Aftersales Service Manual Gearbox-Retarder-System GO170 - GO210 With R 115 E

Training Aftersales Service Manual
Gearbox-Retarder-System GO170 - GO210 with R 115 E
'DLPOHU&KU\VOHU$* Aftersales Service Manual Gearbox-Retarder-System 9RLWK7XUER*PE+ &R.*

3RZHUWUDLQ%XVLQHVV8QLW cbtd 2000-01 53.2687.10
Product unit retarder
7UDQVPLVVLRQV
Content 7DEOHRI&RQWHQWV
1 Preface ....................................................................................................1/1
2 General....................................................................................................2/1
2.1 Illustration Gearbox-Retarder-System ............................................................. 2.1/1
2.2 Function and Operation Scheme Gearbox ...................................................... 2.2/1
2.3 Function and Operation Scheme Retarder ...................................................... 2.3/1
2.4 Gearbox Identification...................................................................................... 2.4/1
2.5 Retarder Identification...................................................................................... 2.5/1
2.6 Retarder Control-Unit Identification ................................................................. 2.6/1
3 Maintenance............................................................................................3/1
3.1 Maintenance Work / Oil Change Intervals ....................................................... 3.1/1
3.2 Checking Oil Level of Gearbox ........................................................................ 3.2/1
3.3 Checking Oil Level of Retarder........................................................................ 3.3/1
3.4 Oil Change of Gearbox .................................................................................... 3.4/1
3.5 Oil Change of Retarder.................................................................................... 3.5/1
4 Diagnosis / Troubleshooting Gearbox .....................................................4/1

4.1 Troubleshooting Diagram A to E...................................................................... 4.1/1

3RZHUWUDLQ%XVLQHVV8QLW cbtd 2000-01 53.2687.10 3URGXFWXQLWUHWDUGHU
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5 Diagnosis / Troubleshooting Retarder.....................................................5/1

5.1 Troubleshooting Diagram A to C ..................................................................... 5.1/1
Electrical Connectrions Diagram ..................................................................... 5.1/6
5.2 Troubleshooting and Remedies....................................................................... 5.2/1
5.3 Illustration Control System............................................................................... 5.3/1
5.4 Checking Supply-Air Pressure......................................................................... 5.4/1
5.5 Checking Constant-Air Pressure (py)............................................................... 5.5/1
5.6 Checking Control Current of Proportional Valve.............................................. 5.6/1
5.7 Checking Temperature Adaption ..................................................................... 5.7/1
5.8 Checking Pressure Sensor .............................................................................. 5.8/1
5.9 Checking Pump Pressure ................................................................................ 5.9/1
5.10 Table of Measurements ................................................................................. 5.10/1
5.11 Operational Check ......................................................................................... 5.11/1
6 Removing, Installing Gearbox .................................................................6/1

6.1 Removing, Installing Gearbox.......................................................................... 6.1/1
7 Removing, Installing Retarder .................................................................7/1

7.1 Removing, Installing Retarder ......................................................................... 7.1/1

(Continue)
8 Repair Gearbox .......................................................................................8/1

8.1 Overall Illustration of Main Components.......................................................... 8.1/1
8.2 Removing, Installing Front Housing Cover, Cover Countershaft and
Closing Cover 5./6.-Gear ................................................................................. 8.2/1
8.3 Removing, Installing Shift ................................................................................ 8.3/1
8.4 Removing, Installing Breather.......................................................................... 8.4/1
8.5 Removing, Installing Sensor/Switch at Gearbox.............................................. 8.5/1
8.6 Removing, Installing Clutch Servo
and Adjusting Wear Indicator .......................................................................... 8.6/1
8.7 Removing, Installing Output Flange
Renewing Radial Shaft Sealing Ring............................................................... 8.7/1
9 Repair Retarder.......................................................................................9/1
9.1 Overall Illustration of Main Components.......................................................... 9.1/1
9.2 Removing, Checking and Installing Casing Ventlation .................................... 9.2/1
9.3 Removing, Cleaning and Installing Silencer .................................................... 9.3/1
9.4 Removing, Installing Water Neck..................................................................... 9.4/1
9.5 Removing, Checking, Installing Heat Exchanger............................................. 9.5/1
9.6 Removing, Installing Oil Tank Cover ............................................................... 9.6/1
A Top Oil Tank Cover ..................................................................................... 9.6/1
B Bottom Oil Tank Cover ................................................................................ 9.6/2

(Continue)
10 Control Parts Retarder ..........................................................................10/1

10.1 Removing, Installing Proportional Valve ........................................................ 10.1/1
10.2 Removing, Installing Oil Temperature Pick-Up.............................................. 10.2/1
10.3 Removing, Installing Cooling-Water Temperature Pick-up............................ 10.3/1
10.4 Removing, Installing Pressure Sensor........................................................... 10.4/1
11 Annex ....................................................................................................11/1
Data Sheet
Conversion Table
Operating Specifications: - Oil Specifications Gearbox

- Oil Specifications Retarder
- Cooling Water Quality
Spare Parts Lists
Other Information

Preface 3UHIDFH
The present service manual serves as training material for the training. The information and instructions
which are given to you furthermore provide the basis for appropriate and professional maintenance and
repair at the gearbox-retarder-system.
We ask you firmly to notice the safety and warning notes which you will find in these instructions.
Caution!
is associated for safety instructions and for warning notes at dangerous situation for persons, at reduc-
tion of quality of workmanship and the possibility of damage to property.
Note
is associated for general notices for a better handling during maintenance

of the gearbox-retarder-system.

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Preface 3UHIDFH
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Caution!
• The switched-on retarder will not secure the parked vehicle!
• During a failure of the Retarders, or while the temperature-adaptation is effective, the vehicle-
speed must be settled by using the service-brake and the lowest possible gear is in use (increase
of the engine-speed). This vehicle condition must be held as long as the retarder again is available
with its full performance.
• Unauthorized changes at the gearbox-retarder-system as well as the use of spare parts,

accessories, attachments and special-productions, not tested and released from Voith, can
influence the security of the entire vehicle negatively. No liability takes place for damages resulting
from it
• The gearbox-retarder-system is built after the state-of -the-art technology and the recognized
safety-related rules. Nevertheless dangers and damages can originate during improper use,
maintenance and repair.
• We will take on no liability for injuries and/or damages, that originate through non-observance of
the security-hints of the service manual or through injuries of the diligence-duty with the handling,
at the service, with the care and maintenance or repair of the gearbox-retarder-system.
• Repair and maintenance work may only be enforced by qualified specialist-staff.

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Preface 3UHIDFH
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Note
• The used position numbers used in this manual corresponds to the position numbers in the spare
parts lists in chapter 9 „Annex“.
Exception:
Items or parts with one -, as well as two-digit position-numbers are no spare parts and not listed in
the spare parts lists.
Items and parts from the retarder sector shown with an oblique number are no spare parts and
therefore not listed in the spare parts lists.
• The terms of the parts for the gearbox correspond to the DaimlerChrysler-EPC-documentation.
Example: 26 / 100 / 35
gearbox-design-group image board part in drawing

• Inevitably, it is impossible for us to warn at each position in these service manual to assess all
situations which might entail the risk of injury for the person carrying out the work. It is therefore
imperative that any person carrying out repair work on the gearbox-retarder-system uses his pro-
fessional knowledge to make sure that his own safety is not endangered and that the retarder suf-
fers no negative effects, in particular safety-wise, through the chosen working procedure. For these
reasons, no liability can be assumed for damage incurred.
• The pertinent accident-prevention-regulation, other broadly rules of the security-technology and

working-medicine and the traffic admission law are to be kept. We are not liable for damages, that
originate through contempt of these rugulations.

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Preface 3UHIDFH
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• With the contact with oils, greases and other chemical substances, the current safety regulations
for these products are to be heeded!
• Caution with the contact with hot fuels! Danger of burn and scald!
• Please read the hints in the operation manual to the safe, proper and economic operation
of the retarder gearbox-retarder-system.
• Should you have any queries and queries about the working steps not described in this manual,
please contact the responsible person in the appropriate organisation of the country involved or:
DaimlerChrysler AG Voith Turbo GmbH & Co. KG

Business unit gearbox Production group retarder
Sales Voithstraße 1
Hauptstraße 107 Post box 15 55
D-76568 Gaggenau D-74555 Crailsheim
Telephone 07225 / 61-65 56 Telephone 07951 / 32-401, -422

Fax 07225 / 61-65 51 Fax 07951 / 32-756
e-mail: e-mail:
sales.transmissions@daimlerchrysler.com retarder@voith.de
Copyright October 1999 - Voith Turbo / DaimlerChrysler

3URGXFWXQLWUHWDUGHU
General *HQHUDO
2.1 Illustration Gearbox-Retarder-System........................................................2.1/1
2.2 Function and Operation Scheme Gearbox.................................................2.2/1
2.3 Function and Operation Scheme Retarder.................................................2.3/1
2.4 Gearbox Identification ................................................................................2.4/1
2.5 Retarder Identification ................................................................................2.5/1
2.6 Retarder Control-Unit Identification ............................................................2.6/1

General ,OOXVWUDWLRQ*HDUER[5HWDUGHU6\VWHP
Illustration gearbox-retarder-system
26/250/047 26/400/089 26/250/068 3700
26/100/116 Screw plug oil sieve
M38x1,5
Inhex.-head, w.a.f. 17
(removing height 120 mm)
26/100/122 Oil filler plug gearbox
M24x1,5
26/100/125 Oil drain plug gearbox
M24x1,5
(bottom)
26/100/206 Speedometer sensor
26/250/047 Switch for starter lock *
26/250/068 Inductive sensor for overspeed
protection *
26/400/083 Oil temperature pick-up
gearbox *
26/400/089 Switch reversing light *
3500 Screw plug with sieve
M30x1,5 26/100/125 26/100/122 26/100/125 3500
3700 Proportional valve
retarder control 26/400/083 26/100/116 26/100/206
* = optional
M+P-07A-1708
M+P-07A-1708
Remark:
Terms of parts from DaimlerChrysler-EPC-documentation

DAIMLERCHRYSLER
7UDQVPLVVLRQV Page 2.1/1
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25/250/068 Clutch servo * 26/350/ 4100 6400

26/150/ Drive shaft
26/250/ Clutch wear indicator *
26/250/068 Inductive sensor for overspeed
protection *
26/350/ Shift
26/400/089 Switch reversing light *
3700 Proportional valve retarder
control
4100 Oil filler screw retarder 3700
M30x1,5
6400 Heat exchanger retarder
* = option
26/150/ 25/250/068 26/250/068
26/250/047 26/250/ 26/400/089
M+P-07A-1710
Remark:
Terms for items from DaimlerChrysler-EPC-documentation

DAIMLERCHRYSLER
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(Continue)
100/1 Retarder data plate

103 Screw plug
Measure point pump pressure 3700
M12x1,5 100/1
107 Oil drain plug retarder
M24x1,5
3500 Screw plug with sieve 3500
M30x1,5
4200 Oil drain plug oil tank
M24x1,5 103
6400
6400 Heat exchanger
107
4200
M+P-07A-1484

DAIMLERCHRYSLER
General )XQFWLRQDQG2SHUDWLRQ6FKHPH*HDUER[
Illustration gearbox force diagram

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Illustration gearbox-longitudinal section
9 10 11 18 12 13 18 14 15 18 16 17 18 19
5 7 4 3 2 1 6 8
1 1. Gear wheel
2 2. Gear wheel
3 3. Gear wheel
4 4. Gear wheel
5 5. Gear wheel
6 Reverse gear wheel
7 Countershaft
8 Oil pump
9 Drive shaft
10 Pilot bearing
11 Switch lever
12 Switch rails
13 Sliding sleeve
14 Synchromesh ring
15 Synchromesh body
16 Synchromesh cone
17 Mainshaft
18 Actuating lever
19 Fly wheel

3URGXFWXQLWUHWDUGHU
Illustration gearbox-longitudinal section
9 10 11 18 12 13 18 14 15 18 16 17 18 19
5 7 4 3 2 1 6 8
1 1. Gear wheel
2 2. Gear wheel
3 3. Gear wheel
4 4. Gear wheel
5 5. Gear wheel
6 Reverse gear wheel
7 Countershaft
8 Oil pump
9 Drive shaft
10 Pilot bearing
11 Switch lever
12 Switch rails
13 Sliding sleeve
14 Synchromesh ring
15 Synchromesh body
16 Synchromesh cone
17 Mainshaft
18 Actuating lever
19 Fly wheel

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Illustration gearbox-sectional view
11 12 20
25
21
26
27 22
23
18
7 17
24
28
7 Countershaft
11 Switch lever
12 Switch rails
17 Mainshaft
18 Actuating lever
20 Cross shift
21 Reverse gear lock
22 Actuating lever bolt
23 Gearbox housing
24 Loose wheel bearing
25 Shift link (option)
26 Shift ramifications
27 Cam follower
28 Reverse idler gear

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General )XQFWLRQDQG2SHUDWLRQ6FKHPH5HWDUGHU
Illustration retarder
70 47 15 17 4
18 26 A R
42 21
23 72
36
25
20
2 1/1 1 1/2
63
19
46
22
6
44
64
69 8 4 16
62
43
55 41
Oil sump Coolant (water)

Supply-air pressure p V Pump pressure p P
Constant-air pressure p y
FD914be
Note
The reference numbers indicated in section 2.3 are not identical with the reference numbers of the spare parts lists.
1 Heat exchanger complete

1/1 Retarder oil-cooling circuit
1/2 Gearbox oil-cooling circuit
2 Control unit
4 Connection Terminal 15
6 Fuse (8A)
8 Connection Ground
15 ABS-signal
16 Retarder stage switch
17 Retarder pilot light
18 Stop light relay
19 Cooling-water temperature pick-up
20 Oil temperature pick-up
22 Ventilation
23 Casing ventilation
25 Air pressure line “A” constant-air pressure (py)
26 Air pressure line supply-air pressure (pv)
36 Ventilation line “R”
41 Oil duct
42 Oil tank
43 Oil sump
44 Stator
46 Rotor
47 Speedometer signal
55 Oil-drain plugs
62 Pressure regulating valve
63 Check valve (inlet)
64 Check valve (outlet)
69 Plug ISO-interface
70 Plug additional functions
72 Pressure sensor

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Description of the function

The Voith retarder 115 E is a powerful, hydrodynamic continous brake of compact design.
The retarder is driven and braking torque is transmitted by pinions in the gearbox.
The transmission ratio enables the retarder to achieve high braking torques right down to low r.p.m. ranges
with the compactest configuration (small rotor/stator).
Retarder braking torque is sustained even when gear changes are made.
The switched-on retarder will not secure the parked vehicle.
In the event of a retarder failure or when the temperature adaption is effective, the service brake must be
used to regulate the vehicle speed.

(Continue)
Action of the retarder R 115 E with Digiprop control system

c
A retarder stage switch (16) with 5 switch stages is used to operate the Voith retarder 115 E.
In a special version, the retarder stage switch (16) in conjunction with ABS can be combined with a
3-stage treadle brake valve or a pressure switch unit for the service brake.
When the retarder stage switch (16) is shifted to position 1, the function „Constant Speed“ is activated.
The present speed is memorized and the retarder holds the vehicle to this speed downhill within the limit a b
of the maximum possible braking torque.
If the retarder is switched-off (position 0), or if a braking stage is engaged (position 2 to 5), the memorized
„Constant Speed“ is deleted. If the function „Constant Speed“ is re-activated the new present speed is
memorized.
FD299
When shifting the retarder stage switch (16) into position 2 to 5, the retarder brakes in
braking stage 1 to 4. The hydrodynamic principle
a Rotor (46)
In the maximum position of the retarder stage switch (16) the braking torque of the Voith retarder is at b Stator (44)
maximum. c Oil flow
The control medium for the Voith retarder 115 E is compressed air, which is taken from the
vehicle air-tank for auxiliary equipment.
When the retarder stage switch (16) is operated, an input signal is fed to the control unit (2).
From this input signal, the control unit (2) provides a control current which is passed on to the
proportional valve (21).
The proportional valve (21), depending on the magnitude of the control current, provides a constant-air
pressure (py) on the oil sump (43).
The constant-air pressure (py) in the oil sump (43), depending on the operating conditions (prop-shaft
speed), forces a certain quantity of oil into the working chamber between rotor (46) and stator (44).
The rotor (46) is connected with the drive shaft of the retarder, the stator (44) is fixed to the
retarder housing.

(Continue)
The rotation of the retarder sets the oil in motion and circulates it in a closed circuit between
the rotor (46) and stator (44).
The reduction of the velocity of the oil flow in the chambers of the stator (44) leads to braking of
the rotor (46) and consequently to braking of the vehicle.
During braking, the deceleration energy is transformed into heat. To dissipate this heat, part of the oil in
the working circuit is pumped continuously by the rotor (46) through the heat exchanger (1) and
filling ducts and returned to the circuit again.
In the heat exchanger (1), the heat energy of the oil is transferred to the cooling water of the vehicle and
dissipated via the vehicle radiator to the ambient air.
The gearbox- and retarder oil reservoires are seperated from each other at the gearbox-retarder-system.
Both oil circuits are cooled down independently in a 3-chamber steel heat exchanger of the retarder -
without limited compromizes.
Temperature pick-ups, water (19), oil (20)

The temperature pick-ups are installed in the cooling system of the vehicle (cooling-return circle from the
retarder to the the heat exchanger) and in the retarder oil duct and transmit signals on cooling water and
oil temperature to the control unit (2).
To prevent the temperatures preset in the control unit (2) for water and oil being exceeded, the retarder
braking torque is adapted to protect the vehicle cooling system and the retarder.
The braking torque and consequently the heat generated are reduced until a balance is obtained bet-
ween the braking energy of the retarder and the amount of heat which can be dissipated by the vehicle
cooling system.
If the cooling water temperature rises into the temperature adaption range, the consequence is an ad-
aption of the retarder braking torque to protect the vehicle cooling system. If the temperature rises above
the temperature adaption range, there is no more braking torque output.

(Continue)
While the temperature adaption is effective or if there is a retarder failure, the service brake must be used
to control the vehicle.
Additionally the control unit cuts back braking torque if oil temperature rises too rapidly - irrespective of
actual oil temperature.
Pressure regulating valve (62)

The pressure regulating valve (62) adjusts the lubrication in the no-load operation of the retarder.
Casing ventilation (23)

During braking, the oil displaces the air present in the working circuit via the casing ventilation (23) and
the ventilation system (22) out of the retarder.
Once the working circuit is free of air, a float rises and closes the casing ventilation.
Non-return valve (63) inlet

When the retarder is switched on, the oil sump is pressurized, causing the check valve (63) to open and
the oil to enter the working space.
Non-return valve (64) outlet

The oil pressure in the working space opens the check valve (64), causing the oil to enter
the heat exchanger (1), to be cooled and to be returned to the working circuit.
Note
If the check valve (outlet) must be renewed during a repair operation, please contact
Voith Turbo or a responsible contract party.

General *HDUER[,GHQWLILFDWLRQ
The gearbox identification (data plate) s located

at the side of the retarder-gearbox-system on
the right in direction of travel
(see illustration 2 – example).
Note
For queries or when ordering spare parts we

need the data of the gearbox.
Only with this data a fast and effective run time Ratio 1. gear
Unit Number of gears
is possible. Series Input torque (x 10)
Version Gearbox-Bus
DAIMLERCHRYSLER Left hand drive
Indic. Serial No
71 4. 692 L GO 170 - 6 / 8,2
Code
DAIMLERCHRYSLER
Indic. GO 170-6/8,2 Serial No Gearbox number
Code G 714.100 L
M-Code
Gearbox part-No
Version No
M-Code
Variant No
M+P-07A-1705e M+P-07A-1704e
Illustration 1 Illustration 2

General 5HWDUGHU,GHQWLILFDWLRQ
The retarder identification (data plate) is

located at the gearbox-retarder-system on the
right in direction of travel (see Illustration 2).
Note
Retarder ratio Serial-Number (Brake-Number)
For queries or when ordering spare parts we (i Ret) 6-digit number
need the data of the retarder.
Only with this data a fast and effective run time
is possible.
Serial-No 000000
CW/Year 45/1999
Date of production
Serial-No
CW/Year
Voith Item-Number DaimlerChrysler part-number
8-digit number
M+P-07A-1706e
M+P-07A-1707
Illustration 1 Illustration 2

DAIMLERCHRYSLER
General 5HWDUGHU&RQWURO8QLW,GHQWLILFDWLRQ
The Digiprop-control unit identification (data

plate) is located at the control unit and provides
the following information:
1. Voith-number
8-digit number
The software version can be identified by
the last two numbers.
Example: .12 = version 1.2 Vo
it
Co h-N
Se de-Nr.:
Kurien- r.: 53
nd Nr. .
en :
-N xx xxxx
r.: x .12
xx
2. Code-number xx
/D
atu
m
3-digit number
(Adjustment of the control unit)
3. Serial-number
5-digit number
with date of coding
4. Client-number
(DaimlerChrysler part-number)
Voith no.:
Code no.:
Note Serial no.: Date:
For queries or when ordering spare parts we
Client no.:
need the data of the control unit.
Only with this data a fast and effective run time M+P07A-1617a
is possible.

Maintenance 0DLQWHQDQFH
3.1 Maintenance Work / Oil Change Intervals..................................................3.1/1
3.2 Checking Oil Level at Gearbox...................................................................3.2/1
3.3 Checking Oil Level at Retarder ..................................................................3.3/1
3.4 Oil Change at Gearbox...............................................................................3.4/1
3.5 Oil Change at Retarder ..............................................................................3.5/1

7UDQVPLVVLRQV Page 3.1
Maintenance 0DLQWHQDQFH:RUN2LO&KDQJH,QWHUYDOV
Maintenance work
The following maintenance work has to be carried out at each oil change (gearbox and retarder):
- Clean the oil sieve (gearbox)

- Clean the sieve for the pressure regulating valve (retarder)
- Check fastening screws of the retarder heat exchanger
- Check all screw plugs on leak and correct fitment
- Carry out visual inspection on leak and existing damages
Please note the following data into the service overview of the Operation Manual „Gearbox-Retarder-System / GO170 - GO210 with R 115 E”:
- maintenance work been carried out

- the oil grade used for the oil change

(Continue)
Gearbox Retarder 6)
Single-grade Synthetic oil 1) Single-grade Synthetic oil 2) Synthetic oil 3)
mineral oil 1) mineral oil 2)
Normal duty 100 000 km 4) 300 000 km 5) 135 000 km 4) 180 000 km 5) 300 000 km 5)
Heavy duty 50 000 km 4) 300 000 km 5) 60 000 km 4) 90 000 km 5) 300 000 km 5)
1) according to Operating Specifications, page 11/4 - 11/7

2) according to Operating Specifications, page 11/8 - 11/12
3) according to Operating Specifications, page 11/13
4) change oil at the latest after 1 year, if fewer kilometres are travelled
5) change oil at the latest after 2 years, if fewer kilometres are travelled
6) The oil change intervals for the retarder oils (see note 2) may adapted to the oil change intervals of the single-grade mineral oils for the gearbox

(Continue)
1. „Normal duty“
Example:
– Long distance traffic
2. „Heavy duty“
Subject to more than normal stress.
Example:
– Use in regions with high ambient temperature (e.g. Saudi-Arabia)
– High max. permissible weight with low rated engine power (< 5,9 kW/metric ton)
– Streches with lots of hills and valleys
– Extreme short-distance traffic with lots of gradients
The given maximum specified figures can be lowered, if overall maintenance cycles for the vehicle are
improved.
With a total-life of the retarder of more than 10%, covered on the vehicle-performance, as well as other
factors not mentioned here also affect the ageing of the oil, it may be necessary to shorten the intervals
between oil changes in individual cases.
For use in extremely cold zones, oils in an appropriately lower viscosity class must be used.
In doubts please contact the service departement.

Maintenance &KHFNLQJ2LO/HYHODW*HDUER[
Illustration checking oil level

26/100/122 Oil filler plug M24x1,5
Inhex.-head, w.a.f. 14, 47 Nm
26/100/128 Sealing ring A24x29
renew
26/100/122
26/100/128
M+P-07A-1716a
Remark:

(Continue)
Note
For satisfactory gearbox operation, it is important to adhere to the specified service filling (see annex)
for operating the retarder in the relevant application.
For the oil level check, the temperature of the gearbox oil must have reached the operating temperature.
The oil level check must be carried out with the vehicle in a horizontal position.
Caution! Risk of injury!
The oil filler plug is hot! Oil temperature!

(Continue)
Job scope
The oil filler plug is hot! Oil temperature! 26/100/122
26/100/128
1. Screw out oil filler plug (26/100/122) and remove sealing ring (26/100/128).
The oil level is correct, if the oil level is at the lower edge of the oil check hole (see illustration right).
2. Top up slowly any lacking oil through the hole for the oil filler plug according to the
Operation Specifications. Remark:
Note
If there is any lacking oil, the gearbox must be checked for outer leaks.
3. Screw in oil filler plug with new sealing ring and screw them tight.
Tightening torque oil filler plug (26/100/122) 47 Nm

Maintenance &KHFNLQJ2LO/HYHODW5HWDUGHU

A Oil drain and measure method
107 Oil drin plug M24x1,5

65 Nm (80 Nm)
4200 Oil drin plug M24x1,5
65 Nm (80 Nm)
4200
107
M+P-07A-1712

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B With oil check plug
4100
109 Oil check plug M24x1,5
65 Nm (80 Nm)
4100 Oil filling plug M30x1,5
100 Nm (150 Nm)
109
M+P-07A-1713

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Note
Two methods are available for checking the oil level:

For satisfactory retarder operation it is important to adhere to the specified service filling of 7,0 litres and
to use only oils specified in the operating Specifications (see annex) for operating the retarder in the
relevant application.
For the oil level check, the temperature of the gearbox oil must have reached the operating temperature.
The oil level check must be carried out with the vehicle in a horizontal position.
Caution!
Two version of the screw plugs (107, 4100, 4200) are possible:
A) Version with integrated FPM-sealing ring;

these corresponds the standard version at the time going to print.
The integrated sealing rings must be checked during the oil level check for possible damages; replace
completely if necessary.

(Continue)
B) Version with loose inserted copper-sealing ring.
In this Aftersales Service Manual is excluding the variant A (series version) described.
If screw plugs with loose inserted copper-sealing rings (variant B) are used, the tightening torques in
brackets are valid. The copper-sealing rings are generel to renew.
Job scope
1. Push a clean vessel under retarder.
The oil drain plugs (107, 4200) and oil filler plug (4100) are hot! Oil temperature!
During the oil level check the retarder mustbe switched-off!

If the retarder is switched-on during working step 2 and screwed out oil drain plugs and/or oil filler plug,
high risk of injury exist by hot leaving oil (increased pressure)!
2. Screw out oil drain plugs and drain oil in clean vessel. 4200
107
3. Check sealing rings of oil drain plugs for damages, renew oil drain plugs if necessary.
4. Screw in oil drain plugs and screw them tight.

Tightening torque oil drain plugs (107, 4200) 65 Nm (80 Nm)

(Continue)
5. Measure drained oil.
6. Top up any lacking oil according to the Operating Specifications, chapter 3.1: „Oil Change Intervals“
and chapter 11: „Annex“.
7. Fill in slowly, over a time period longer than 3 minutes, the quantity of oil specified in the bore of
the oil filler plug (4100).
Caution!
The retarder must only be filled with oil via the bore of the oil filler plug (4100)!
Note
With determined lacking oil quantity check retarder for possible outer leak.
8. Check sealing ring of oil filler plug for possible damages, renew oil filler plug if necessary.
9. Screw in oil filler plug and screw it tight.

Tightening torque oil filler plug (4100): 100 Nm (150 Nm)
Caution!
Operate the retarder, after checking oil level, first time during a trail run at a speed of minimum 50 km/h
5 times for approx. 5 seconds each time in position 2 at the retarder stage switch
(corresponds braking stage 1).

(Continue)
Job scope
1. Switch vehicle ignition system „OFF“ and then „ON“ again (reset).
2. Operate the retarder in stand-still in switch position 2 at the retarder stage switch
(corresponds braking stage 1) and switch it off after approx. 5 seconds.
Repeat this procedure twice.
3. Switch off the retarder and wait 5 minutes.
The oil check plug (109) and oil filler plug (4100) are hot! Oil temperature! 4100
While the oil level is being checked, the retarder must be switched off!
If the retarder is switched-on during working step 4 and screwed out oil drain plugs and/or oil filler plug,
high risk of injury exist by hot leaving oil (increased pressure)!
4. Screw out oil check plug (109).

The oil level is correct, if it is at the lower edge of the oil check hole (see illustration).
Caution!
109
M+P-07A-1713

(Continue)
5. Fill in slowly the quantity of oil, via the bore of the oil filler plug, specified in accordance to the
Operating Specifications.
Note
With determined lacking oil quantity check retarder for possible outer leak.
6. Check sealing ring of oil check plug for possible damages, renew oil check plug if necessary.
7. Screw in oil check plug and screw it tight.

Tightening torque oil check plug (109): 65 Nm (80 Nm)
8. Check sealing ring of oil filler plug (4100) for possible damages, renew oil filler plug if necessary.
9. Screw in oil filler plug and screw it tight.


Maintenance 2LO&KDQJHDW*HDUER[
Illustration oil change

26/100/128
26/100/107 Oil sieve 26/100/122
clean sieve with appropriate
cleaning agent (Benzine)
26/100/113 Spring 26/100/116
26/100/116 Screw plug (oil sieve)
M38x1,5 26/100/119
26/100/119 Sealing ring A38x46 26/100/107
renew
26/100/122 Oil filler plug M24x1,5
26/100/113
26/100/125 Oil drain plug M24x1,5
26/100/128 Sealing ring A24x29
renew 26/100/128
26/100/125
Lubricants and cleaning agents
Sieve in screw plug Benzine

26/100/128
M+P-07A-1715
26/100/125
Remark:

(Continue)
Note
For satisfacory retarder operation, it is important to adhere to the specified service filling (see table
below) and to use only oils specified in the Operating Specifications (see annex) for operating the
retarder in the relevant application.
For draining the oil the temperature of the gearbox oil must have reached the operating temperature.
The oil drain plugs are hot! Oil temperature!
Oil filling
Service filling (oil change) 12,5 litre
New filling 13,0 litre

(Continue)
Job scope
26/100/122 26/100/128
1. Push an oil pan under the gearbox.
26/100/116
26/100/119
Caution! Risk of injury! 26/100/107
26/100/113
The oil drain plugs (26/100/125) are hot! Oil temperature!
2. Screw out oil drain plugs (26/100/125), remove sealing rings (26/100/128) and drain oil. 26/100/128
26/100/125
3. Screw the oil drain plugs (26/100/125) with new sealing rings tight.
Tightening torque oil drain plugs (26/100/125): 47 Nm 26/100/128
26/100/125 M+P-07A-1715b
4. Screw out screw plugs (26/100/116) and remove sealing rings (26/100/119).
Remark:
5. Clean oil sieve (26/100/107) with appropriate cleaning agent (Benzine) and blow it out with Terms of items from DaimlerChrysler-EPC-documentation
compressed-air. Check cleaned sieve for possible damages, renew if necessary.
6. Fix spring (26/100/113) with oil sieve (100/107) in bore of screw plug (26/100/116).
7. Screw the screw plug (26/100/116) with new sealing ring tight.
Tightening torque screw plug oil sieve (26/100/116): 60 Nm
8. Screw out oil filler plug (26/100/122) and remove sealing ring (26/100/128).
9. Fill in slowly oil via the bore of the oil filler plug according to the Operating Specifications.
10. Screw the oil filler plug (26/100/122) with new sealing ring tight.
Tightening torque oil filler plug (100/122): 47 Nm

Maintenance 2LO&KDQJHDW5HWDUGHU
Illustration oil change retarder

4100
107 Oil drain plug M24x1,5
65 Nm (80 Nm)
3500 Screw plug with sieve M30x1,5
100 Nm (150 Nm),
Clean sieve with appropriate
cleaning agent and blow out with
compressed-air
4100 Oil filler plug M30x1,5
100 Nm (150 Nm)
4200 Oil drain plug oil tank M24x1,5
65 Nm (80 Nm)
Lubricants and cleaning agents
O-rings Silicone- free and

non-corrosive grease
107
Sieve Benzine
in screw plug
3500 4200 4200
M+P-07A-1488

(Continue)
Note
For satisfacory retarder operation, it is important to adhere to the specified service filling (see table on
next page) and to use only oils specified in the Operating Specifications, chapter 3.1 „Oil Change Inter-
vals“ and chapter 11: „Annex“ for operating the retarder in the relevant application.
For draining the oil the temperature of the retarder oil must have reached the operating temperature.
Ensure that during the entire oil change no constant-air pressure acts on the retarder, that means the
retarder must be switched off!
Caution!
Two versions of screw plugs (107, 3500, 4100, 4200) are possible:


(Continue)
Oil filling with heat exchanger
Service filling (oil change, oil level check) 7,0 litre
After complete taking apart and cleaning as well as

emptied heat exchanger (corresponds new filling) 7,8 litre
Job scope
1. Push an oil collecting pan under the retarder.
The oil drain plugs (107, 4200) are hot! Oil temperature!
2. Screw out the oil drain plugs (107 and 4200) and drain the oil.
3. Check sealing rings of oil drain plugs on possible damages, renew oil drain plugs if necessary.
107
4. Screw the oil drain plugs tight.
Tightening torque oil drain plugs (107, 4200): 65 Nm (80 Nm)
4200 4200
M+P-07A-1489

(Continue)
5. Screw screw plug with sieve (3500) out of the retarder.
6. Clean sieve in screw plug with appropriate cleaning agent (Benzine) and blow it out with
compressed-air.
7. Check sealing ring of screw plug with sieve on possible damages, renew screw plug if necessary.
8. Fit screw plug with sieve and screw it tight.

Tightening torque screw plug (3500): 100 Nm (150 Nm)
3500
9. Screw out oil filler plug (4100).
M+P-07A-1490
Achtung!
10. Fill in slowly in the bore of the oil filler plug, over a time period longer than 3 minutes, the quantity
of oil specified (see table page 3.5/3 in this chapter) according the Operation Specifications,
chapter 3.1: „Oil Change Intervals“ and chapter 11: „Annex“.
This working step is necessary for the correct bleeding of the retarder system.

(Continue)
11. Check sealing ring of oil filler plug on possible damages, renew oil filler plug if necessary.
12. Fit oil filler plug and screw it tight.

Caution!
Operate the retarder after the oil change first during the trial run 5 times with a speed of minimum 50 km/h
each time for approx. 5 seconds in position 2 at the retarder stage switch (corresponds braking stage 1).

Diagnosis / 'LDJQRVLV7URXEOHVKRRWLQJ*HDUER[
Troubleshooting
4.1 Troubleshooting Diagram ...........................................................................4.1/1

Troubleshooting Master System .................................................................................... 4.1/1
Troubleshooting Diagram A to E.................................................................................... 4.1/2

Diagnosis / 7URXEOHVKRRWLQJ'LDJUDP
Troubleshooting
Illustration troubleshooting master-system
see see
troubleshooting at troubleshooting
at
diagram Complaint retarder? diagram
gearbox?
at page 4.1/2 at page 5.1/2
at the
Please contact gearbox-retarder-
DaimlerChrysler system,
but I am not sure

Troubleshooting (Continue)
A1
A2*
A3* *Begin of troubleshooting at A1
E leaks B
elektrical shiftability
function
Complaint
Gearbox
no
noices
traction
D C

Illustration troubleshooting diagram A1
A1
leaks
Check residual oil quantity.

Contact product unit gearbox
if residual oil quantity
smaller 50%.
at the
drive shaft?
YES NO
at radial shaft at countershaft

sealing ring? cover?
YES NO YES NO
Renew radial shaft at cover 5./6.-

seal new with
sealing ring gear?
released
(chapter 8.2) (only GO 210)
surface sealant
(chapter 8.2)
NO YES
at
O-rings?
YES NO A2 at O-ring?
YES NO
Renew O-rings at surface /

(chapter 8.2) surface sealant? at the micro
Renew O-rings capsulated
(chapter 8.2) screws?
YES NO
YES NO
Renew O-rings Contact

(chapter 8.2) product unit
gearbox use new micro Contact
encapsulated product unit
screws gearbox

A2
leaks
at cover
oil pump?
Contact YES NO at parting surface

product unit of housing?
gearbox
YES NO
Contact am
product unit Gehäuseteil?
gearbox
YES NO
at cover of
gearbox selecting
fork right and left?
YES NO
Threaded compo-
seal new with nents / shift rocker
surface sealant arm bearing ?
(chapter 8.3)
NO YES
Contact
Filler cap?
product unit
gearbox
NO YES
Radial shaft
sealing rings of
cross shift?
Radial shaft YES NO Seal parts new,

sealing ring Sensor / switch?
renew if
left side? necessary
YES NO NO YES
A3
renew radial shaft Radial shaft Check sensor /
sealing ring sealing ring switch for leak
(chapter 8.3) right side?
YES NO leaky sealed
Renew cross Contact

Renew parts Seal parts new
shift complete product unit
and seal them
(chapter 8.3) gearbox

A3
leaks
at
breather?
Breather YES NO Cover / flanges

correct mounted? leak?
YES NO YES NO
Check oil level Cover / flanges Paper gasket

Renew breather
and correct damaged? at cross shift
(chapter 8.4)
if necessary leaks between
(chapter 3.2) YES NO inner and outer
cover?
YES NO
Replace Seal new

cover / flanges cover / flanges
(chapter 8.2) (chapter 8.2)
Contact
Paper gasket
product unit
damaged
gearbox
YES NO
Renew Seal new with

cross shift released
complete liquid sealant
(chapter 8.3)

Illustration troubleshooting diagram B
Shiftability
Selectability?
YES NO
outer shift Shift

smooth? at still stand
heavy handling?
NO YES NO YES
Smooth shifting Contact Reverse gear Does clutch

of gear? product unit heavy handling? disconnect?
gearbox
NO YES YES NO NO YES
Contact Contact Contact Adjust clutch Clutch servo

Renew cross
product unit product unit product unit according to vehicle in function?
shift complete
gearbox gearbox gearbox manufacturer
(chapter 8.3)
instructions
YES NO
Contact Change
product unit clutch servo
gearbox (chapter 8.6)

Illustration troubleshooting diagram C
Noices
noices when
shifting?
YES NO
Noices during
in reverse gear? operation
in pulling action?
YES NO YES NO
Check for clutch Check oil level

scratching Noices during
disconnect (chapter 3.2),
when shifting? stress cycle?
according to if OK,
vehicle manufacturer contact product
instructions YES NO unit gearbox NO YES
Ambient Noices during

Contact operation in Contact
temperature? product unit product unit
retarder operation?
gearbox gearbox
COLD WARM YES NO
does not appear Contact Rattleing in

Check outer shift
at operation product unit idle speed?
for easy handling
temperature gearbox
YES NO
Check and adjust

according to the Contact
vehicle manufacturer product unit
instructions: gearbox
- Idle speed
of engine
- torsional absorption
of clutch

Illustration troubleshooting diagram D
no
traction
Gear shifted
at gearbox?
(check at
gearbox)
YES NO
Contact Adjust again

product unit outer shift
gearbox according to the
vehicle manufacturer
instructions

Illustration troubleshooting diagram E
electrical
function
Does switch
exist
(switch for reverse
gear position
or neutral position)
YES NO
Check contacts of Sensors

components available?
OK NOK YES NO
Check contacts of Contact

functioning? Renew
components product unit
components
gearbox
YES NO OK NOK
Contact Renew Renew

functioning?
product unit components components
gearbox
YES NO
Contact
Renew
product unit
components
gearbox

Diagnosis / 'LDJQRVLV7URXEOHVKRRWLQJ5HWDUGHU
Troubleshooting
5.1 Troubleshooting Diagram ...........................................................................5.1/1

Troubleshooting Master System ........................................................................5.1/1
Troubleshooting Diagram A to C .......................................................................5.1/2
Electrical Connections Diagram ........................................................................5.1/6
5.2 Troubleshooting and Remedies .................................................................5.2/1

5.3 Illustration Control System .........................................................................5.3/1
5.4 Checking Supply-Air Pressure ...................................................................5.4/1
5.5 Checking Constant-Air Pressure (py) .........................................................5.5/1
5.6 Checking Control Current of Proportional Valve ........................................5.6/1
5.7 Checking Temperature Adaption................................................................5.7/1
5.8 Checking Pressure Sensor.........................................................................5.8/1
5.9 Checking Pump Pressure...........................................................................5.9/1
5.10 Table of Measurements..............................................................................5.10/1
5.11 Operational Check......................................................................................5.11/1

Troubleshooting
Illustration troubleshooting master system
see see
troubleshooting at troubleshooting
at
diagram Complaint retarder? diagram
gearbox?
at page 4.1/2 at page 5.1/2
at the
Please contact gearbox-retarder-
DaimlerChrysler system,
but I am not sure

Oil loss
through
ventilation
Complaint Retarder
Retarder pilot light B
R 115 E
No respectively
insufficient
retarder braking
effect

Illustration troubleshooting diagram group
Note
It is important that the specific service filling is kept for a trouble-free operation of the retarder (see chapter 3.5 „Oil Change“ and chapter 11 „Annex“).
Oil loss
through
ventilation
Check
retarder oil level
Water in oil? OK NOK

Water in oil?
(emulsion) (emulsion)
NO YES Check YES NO

heat exchanger
(chapter 9.5)
Contact Check
Voith service retarder oil level
partner
too too
high low
Check Check
gearbox oil level gearbox oil level
NOK OK OK NOK
Check
Check
Correct casing ventilation
gearbox oil level Check
retarder oil level (chapter 9.2)
gearbox oil level
too too
high OK NOK too
low too
high low
Correct Contact Check

Replace
retarder- and Voith service control unit Correct
casing ventilation
gearbox oil level partner (chapter 5.4 - 5.9) retarder- and
gearbox oil level
Contact
Voith service
partner
M+P-07A-1763 ae

Retarder
pilot light
Permanent light
in position 0 no function? flashes?
after light test?
Activate
Check
blinking code Temperature
retarder pilot light
and read out adaption
and renew,
fault code
if necessary
(chapter 5.2)
Rectify fault and Check operation

delete Contact (during braking
fault memory Voith with retarder
(chapter 5.2) service partner nominal engine
speed, if
possible)
OK NOK
Check
temperature Driver instruction!
pick-up oil / water
(chapter 5.7)
OK NOK
Check vehicle Replace temperature

cooling system: pick-ups
-coolant level (chapter 10.2, 10.3)
-thermostat
-coolant pump
-radiator fan
-radiator grill for
dirtiness

C
No respectively
too insufficient
retarder braking
effect
Check
retarder oil level
Water in oil? OK NOK

Water in oil?
(emulsion) (emulsion)
NO YES YES NO
Check
heat exchanger
(chapter 9.5)
Check constant-
air pressure (py)
(chapter 5.5) Check
retarder oil level
OK NOK
too too
high low
Check
pump pressure
(chapter 5.9) Contact Check
Voith gearbox oil level
OK NOK service partner
OK NOK
Check current of
Contact Contact
proportinal valve
Voith Voith Check
(chapter 5.6) Correct
service partner service partner gearbox oil level
retarder oil level
OK NOK
too too
high low
Check supply-air Check temperature

pressure adaption/ Contact Correct
(chapter 5.4) pressure sensor Voith retarder- and
(chapter 5.7 / 5.8) service partner gearbox oil level
OK NOK
OK NOK
Check vehicle
Proportional valve
compressed-air
or
pressure system Contact
damping plate Contact
mechanically Voith Voith
OK NOK
defect service partner service partner
Contact Contact
Voith vehicle
service partner manufacturer

Electrical connections diagram R 115 E

(Voith-wiring harness) P U 72
70 47 15 21 19 20
1 2 4 14 13 11 12 10 1 9 5 8 4 3 2 7 6
2 Control unit 18
87 87a 30
4
15
Connection Terminal 15
ABS-signal
. -
2 1
+ + - + -
16 Retarder stage switch

17 Retarder pilot light .
18 Stop light relais .
20 Oil temperature pick-up
47 Speedometer signal 17 X3 X2
69
70
Plug ISO-Interface
Plug optional functions
.4 8 11 10 12 7 9 4 5 6 1 2 3 2 3 1 6 5 4 9 8 7
72 Pressure sensor 2
18 17 16 6 5 4 9 8 10 11 12 13 14 15 7 3 2 1
X1
7 6 5 2 3 8 4
4
3 2 1 4
69
16
FD983a

Diagnosis / 7URXEOHVKRRWLQJDQG5HPHGLHV
Troubleshooting
Troubleshooting and remedies
Requirements for check

l Battery voltage 18 - 32 V
l Vehicle electrical system checked in accordance with the Owner´s Manual for the vehicle and
found satisfactory.
l Fuse for retarder control unit checked and found satisfactory.
l Compressed-air pressure 6 - 11 bar
l For check with the multimeter, pin 15 (plug X1) on the control unit (2)
must be connected to pin 15 ground (terminal 31),
at pin 7 (plug X1) and pin 13 (plug X1) must be connected terminal 15
Note
Prior to any troubleshooting, the retarder oil level must be checked and corrected, if necessary
(see table, chapter 3.5, page 3.5/3).

Note
The retarder pilot light additionally has the function of a fault code:
- slight fault
Permanent light in position 0 - 5 of retarder stage switch, braking is still possible to limited extent.
- serious fault
Permanent light in position 0 - 5 of retarder stage switch,, braking is no longer possible - the retarder is
switched off.
Note
If the ignition is switched off and on, the retarder is in operation again and the retarder pilot light goes off.
If a serious fault remains present or reoccurs, the retarder switches off again and the retarder pilot light
comes on permanently in position 0 to 5 of the retarder stage switch.

Connector arrangement and pin assignment
Note
All plugs illustrated from plug-in side (i.e. leads at back).
Plug X1 control unit

1 Not in use
2 Not in use
3 Not in use
4 Retarder stage switch, Position 2
7 Terminal 15
10 Retarder stage switch + 16 13 10 7 4 1
11 ISO-interface, L-lead
17 14 11 8 5 2
12 ISO-interface, K-lead
13 connected with terminal 15 18 15 12 9 6 3
14 Not in use
15 Terminal 31
16 Output / high side 2 „HS2“
17 Not in use
FD846


1 Not operational
2 Proportional valve -
3 Proportional valve +
4 Cooling-water temperature pick-up -
7 4 1
5 Cooling-water temperature pick-up +
6 Not operational 8 5 2
7 Not in use
8 Oil temperature pick-up - 9 6 3
9 Oil temperature pick-up +
FD848

1 Input / pull up „DIU 1“
2 Speedometer signal
3 ABS-signal
4 Input / pull down „DID 2“
10 7 4 1
6 Pressure sensor ground 11 8 5 2
7 Pressure sensor signal voltage

12 9 6 3
8 Retarder pilot light
10 Pressure sensor supply voltage
11 Stop light relais
12 Input / pull down / PWM-in „DID4“ FD847

Plug optional functions

1 Retarder stage switch +
5 Input / pull down / PWM -in „DID 4“ 2 4 6 8 10 12 14
6 Input / pull up „DIU 1“

1 3 5 7 9 11 13
7 Pressure sensor ground
8 Pressure sensor signal voltage
9 Pressure sensor supply voltage
10 Output / high side „HS1“
12 No function FD849
13 Terminal 15
14 Terminal 31
Plug ISO-interface
1 K-lead
2 L-lead
3 Terminal 15 4 3
4 Terminal 31
2 1
FD854

Plug cooling-water temperature pick-up

Plug oil temperature pick-up
FD851
Plug proportional valve

1 Proportional valve +
2 Proportional valve –
3 No function 4 2
4 No function 1 3
FD850

Plug retarder stage switch

1 Not operational
2 Position 5
3 Position 4
4 Retarder stage switch +
5 6 7 8
5 Position 3
6 Position 2 1 2 3 4
7 Position 1
8 Bridge to pin 4
FD853

A. With fault code

Special tool
53.8224.10
Commercially available tool
Multimeter recommended: Fluke 87
Note
The blinking code of the retarder pilot light with service-cable can be used to obtain a read-out from the
fault memory.

Fault memory readout via retarder pilot light blinking code
Note
If sveral faults have been stored in the memory, they are output in the sequence of their occurence, but
always only one fault per triggering.
Exception:
The fault „Coding Fault“ is not held in the memory but is output via the blinking code.
The blinking code can be read of the control unit service cable or retarder stage switch.
Fault memory readout with service cable
Requirements
l Retarder stage switch in position O.
l Vehicle at standstill, ignition ON
1. Service interface L-lead connected to ground ≥ 2s. For this pupose, press „L - pushbutton“ at
service cable
2. First fault as blinking code output.
3. Item 2 and 3 repeated for more blinking code outputs.
Meaning
l Long blinking signals (2 sec.) tens unit.
l Short blinking signals (0,5 sec.) single unit.

Fault memory read out with retarder stage switch

The blinking code can be triggered with the retarder stage switch during the service function
(vehicle ignition system ON and v = 0):
1. Retarder stage switch in position 0

2. Retarder stage switch in position 1 (≥ 2 seconds)
3. Retarder stage switch in position 0
0,5 sec
0,5 sec
0,5 sec
2 sec
2 sec
1 sec
1 sec
1 sec
1 sec
4. First fault as blinking code
5. Items from ...3 for more blinking code outputs
There is a break of 3 seconds before and after each blinking code output, during this time the retarder
pilot light is switched off. 99-03-fd1620
Display example for fault code 23: Display example for fault code 23
E Retarder pilot light ON

The number of tens units first indicated as long ON time: each 2 seconds A Retarder pilot light OFF
The number of single unit then is indicated as short ON time: each 0,5 seconds t Time
Breaks between each ON time: each 1 second
If an actual fault is available (before triggering the blinking code the retarder pilot light is switched ON)
the retarder pilot light switches to permanent light again after the blinking code.
Is only one stored fault available, the retarder pilot light is OFF after the output.

Delete fault memory

No marginal notes in accordance with fault memory read out.
1. Vehicle ignition system: OFF
2. Servcie interface L-lead connected to ground. For this purpose, press „L-pushbutton“ of
service cable.
3. Vehicle ignition system: ON
4. Release L-lead from ground after ≥ 2 sec.

Note
Meaning of entries in „Measurement/test connection“ column: X 1/15 Ω X3/11

Pin 15 to plug X1, Multimeter set for Ohms, Pin 11 to plug X3
Fault Fault text Fault Trigger time Requirement / Measurement/ Result/ Cause/
class Operation Test Set point Remedy 2)
connection1)
Code Test step
01 Stop light relay/ slight 1s - Ignition: OFF X 3/11 Ω X 1/15 Relay is Check lead, plugs
- Pull plug X3 out of installed: and relay or
Short circuit to control unit 250-350 Ω consumers
ground
1)
X 1/15 = ground control unit
2)
Only, if no fault is recognizable after a complete check of the periphery: change control unit.

class Operation Test connection Set point Remedy
Code Test step
03 HS 1 output slight 1s - Ignition: OFF X 1/18 Ω X 1/15 Relay is Check lead, plugs
Short circuit - Pull plug X1 out of installed: and relay
control unit 250-350 Ω or consumers
04 HS 2 output slight 1s - Ignition: OFF X 1/16 Ω X 1/15 Relay is Check lead, plugs
Short circuit - Pull plug X1 out of installed: and relay
control unit 250-350 Ω or consumers
05 Terminal 15 serious 60 s - Ignition: OFF X 1/7 V X 1/15 ≥ 17,5 V Check lead, plugs
Undervoltage - Pull plug X1 out of and fuses
control unit
- Ignition: ON
06 Terminal 15 serious 10 s - Ignition: OFF X 1/7 V X 1/15 ≤ 32,5 V Checking electrical

Overvoltage - Pull plug X1 out of installation of vehicle
control unit (see manufacturer
- Ignition: ON instructions)
- Start engine
(idle speed)

Fault Fault text Fault Trigger time Requirement / Measure- Result/ Cause/
class Operation ment/ Set point Remedy
Test connec-
tion
Code Test step
08 Cooling-water 1s - Ignition: OFF X 2/5 Ω X 2/4 20°C ± 10°C = Check lead and
09 temperature - Pull plug X2 out of 1039 - 1117Ω sensor
pick-up serious/ control unit
Discontinuity / slight * 60°C ± 10°C =
Short circuit to 1099 - 1271Ω
battery
80°C ± 10°C =
1271 - 1347Ω
Notice:
The measuring
in one tempera-
ture range
normally is
sufficient.
* Fault is in serious class, if temperature pick-up for oil and water are defect at the same time.

class Operation Test connec- Set point Remedy
tion
Code Test step
11 Oil temperature 1s - Ignition: OFF X 2/9 Ω X 2/8 20°C ± 10°C = Check lead and
12 pick-up serious/ - Pull plug X2 out of 1039 - 1117Ω sensor
Discontinuity / slight * control unit
Short circuit to 60°C ± 10°C =
battery 1099 - 1271Ω
80°C ± 10°C =
1271 - 1347Ω
Notice:
The measuring
in one tempera-
ture range
normally is
sufficient.
* Fault is in serious class, if temperature pick-up for oil and water are defect at the same time.

Code Test step
13 1 Retarder stage serious 100 ms - Ignition: ON X 1/10 V X 1/15 ≥ 17,5 V Check lead, plug and
switch - Retarder stage retarder stage switch
Undefined switch: X 1/6 V X 1/15 0V
switch state Position 0 X 1/5 V X 1/15 0V
X 1/4 V X 1/15 0V
X 1/9 V X 1/15 0V
X 1/8 V X 1/15 0V
13 2 - Ignition: ON X 1/10 V X 1/15 ≥ 17,5 V Check lead, plug and

- Retarder stage X 1/6 V X 1/15 ≥ 17,5 V retarder stage switch
switch:
Position 1 X 1/5 V X 1/15 0V
X 1/4 V X 1/15 0V
X 1/9 V X 1/15 0V
X 1/8 V X 1/15 0V

switch: X 1/5 V X 1/15 ≥ 17,5 V
Position 2
X 1/4 V X 1/15 0V
X 1/9 V X 1/15 0V
X 1/8 V X 1/15 0V

Code Test step

switch: X 1/5 V X 1/15 ≥ 17,5 V
Position 3 X 1/4 V X 1/15 ≥ 17,5 V
X 1/9 V X 1/15 0V
X 1/8 V X 1/15 0V

switch: X 1/5 V X 1/15 ≥ 17,5 V
Position 4 X 1/4 V X 1/15 ≥ 17,5 V
X 1/9 V X 1/15 ≥ 17,5 V
X 1/8 V X 1/15 0V

switch: X 1/5 V X 1/15 ≥ 17,5 V
Position 5 X 1/4 V X 1/15 ≥ 17,5 V
X 1/9 V X 1/15 ≥ 17,5 V
X 1/8 V X 1/15 ≥ 17,5 V

Fault Fault text Fault Trigger time Requirement / Operati- Measurement/ Result/ Cause/
class on Test connec- Set point Remedy
tion
Code Test step
14 Retarder stage serious 10 s - Ignition: OFF X 1/10 V X 1/15 0V Check lead and
switch - Pull plug X1 out of plug
Short circuit to control unit
battery - Ignition: ON
- Retarder stage switch:
Position 0
15 Retarder stage serious 1s - Ignition: OFF X 1/10 Ω X 1/15 Resistor Single check of
switch - Pull plug X1 out of infinite stages for
Short circuit to control unit short circuit
battery - Retarder stage switch:
Position 5
16 Speedometer serious 2s - Ignition: ON X 3/2 V X 1/15 ≤ 1V Check lead and

signal speedometer
Discontinuity

tion
Code Test step
18 Speedometer signal serious 2s - Ignition: OFF X 3/2 V X 1/15 ≤ 9V Check lead and
Short circuit to battery - Pull plug X3 out of speedometer
undefined signal control unit
- Ignition: ON
19 ABS serious 60 s - Ignition: ON X 3/3 V X 1/15 ≥ 3,5 V Check lead,

Short circuit to ground relay and
ABS-control unit
21 ABS-Signal undefined serious 60 s - Ignition: ON X 3/3 V X 1/15 ≥ 16,5 V Check lead,

relay and
ABS-control unit
22 Internal fault serious 1s - - - Replace control

ABS-current path unit
23 Proportional valve serious 1s - Ignition: OFF X 2/3 V X 1/15 ≤ 10 V Check lead

Fault No. 1: - Pull plug X2 out of
Short circuit to battery control unit
- Ignition: ON

tion
Code Test step
24 1 Proportional valve serious 1s - Ignition: ON X 2/2 Ω X 2/3 18-25 Ω Check lead and
Fault No. 2: - Pull plug X2 out proportional
- Short circuit proportional of control unit valve
valve magnetic (valve block)
- Short circuit connection
lead proportional valve
- Discontinuity proportio-
nal valve magnetic
Valve magnetic
- Discontinuity connec-
tion lead proportional
valve
- Short circuit to ground at
proportional valve
- Prop.- and shift valve
interchanged
24 2 - Ignition: OFF X 2/3 Ω X 1/15 Resistor Check lead and

- Pull plug X2 out infinite proportional
of control unit valve
(valve block)

tion
Code Test step
24 3 - Ignition: OFF X 2/2 Ω X 1/15 Resistor Check lead and

- Pull plug X2 out of infinite valve block
control unit
25 Valve block serious 10 s Replace

Fault No. 3: control unit
defective control unit
27 Valve block serious 2s Replace

Fault No. 5: control unit
defective control unit
28 Terminal 30 serious 60 s - Ignition: OFF X 1/13 V X 1/15 ≥ 17,5 V Check lead,

Undervoltage - Pull plug X1 out of plug and fuse
control unit
- Ignition: ON

tion
Code Test step
29 Fault control unit serious 180 ms Replace

control unit
31 Control unit: serious 100 ms Provide new

Coding fault parameters for
control unit
32 Retarder pilot light: serious 3s - Ignition: OFF X 3/8 V X 1/15 ≥ 17,5 V Check lead,
Discontinuity / - Pull plug X3 out of retarder pilot
Short circuit to ground control unit light and fuse
- Ignition: ON
33 Retarder pilot light: serious 3s - Ignition: ON X 3/8 V X 1/15 ≤ 2V Check lead and
Short circuit to battery - Retarder stage retarder pilot
switch: light
Position 1
35 Fault control unit serious 500 ms / 123 s Replace

control unit

tion
Code Test step
37 Fault foot operation slight 100 ms / 1 s Check installation in

accordance with
OEM - as well as
Voith requirements
38 1 Fault constant-air slight 1 s to 10 s Ignition: ON X 3/7 V X 1/15 0,3-0,7 V Pressure sensor

pressure Position 0 and wiring harness
X 3/10 V X 1/15 4,75-5,25 V
If deviation: step 2
2 Troubleshooting in
wiring harness,
pressure sensor,
proportional valve,
supply-air pressure,
ECU
(Contact Voith)

B. Without fault code
Note
Retarder faults without fault code are not recognized electronically.

Diagnosis / ,OOXVWUDWLRQ&RQWURO6\VWHP
Troubleshooting
Illustration control system

11
33
71
32 61
Note 25
A
The reference numbers indicated in section 5.3
P
are not identical with the reference numbers of
R
the spare parts lists. 21 26
36
31
1 Heat exchanger
2 Control unit 35 34
11 Connection proportional valve cur-
rent 40
20 Oil temperature pick-up 2
21 Proportional valve 39 20
25 Constant-air pressure line py 29
(connection A)
26 Supply-air pressure line pv
(connection P)
31 Compressed-air line
(pressure regulator-four circuit
protection valve)
32 Compressed-air line (four circuit
protection valve air tank for auxilia-
ry equipment) with test connection 1
(Brake circuit 1)
FD919
(Brake circuit 2)
(Parking brake)
36 Ventilation line
(Connection R)
39 Electrical lead (cooling-water
temperature pick-up to control unit,
2-wires)
40 Electrical lead (oil temperature
pick-up to control unit, 2-wires)
61 Four-circuit protection valve
71 Air tank for auxiliary equipment

Diagnosis / &KHFNLQJ6XSSO\$LU3UHVVXUH
Troubleshooting
Job scope test

1. Connect suitable test pressure gauge to test connection of compressed-air line (32)
(four circuit protection valve - air tank for auxiliary equipment) and check supply-air pressure pv..
Minimum pressure: 6 bar
Maximum pressure: 11 bar
Note
32
If the pressure is not within the specified range, the compressed-air pressure installation must be FD122
checked to the manufacturer´s data.

Diagnosis / &KHFNLQJ&RQVWDQW$LU3UHVVXUHS\
Troubleshooting

l Retarder stage switch in position 0
l Vehicle ignition system OFF
Special tool
53.1403.10
Compressed-air gauge
0-6 bar

Caution!
Two versions of screw plugs (103) are possible:


Job scope test 4100

1. Screw out oil filler plug (4100).
M+P-07A-1488c
2. Connect pressure gauge (99/1) to bore of oil filler plug (4100).

99/1
3. operate retarder in braking stage 5 and compare read-off value with the values of the constant-air
pressure (py) according to table see page 5.10/1.
4. Check sealing ring of screw plug for damages; replace if necessary.
5. Disconnect pressure gauge (99/1). Fit oil filler plug (4100) and screw it tight.
M+P-07A-1488b
99/1 Pressure gauge 53.1403.10

Diagnosis / &KHFNLQJ&RQWURO&XUUHQWRI3URSRUWLRQDO9DOYH
Troubleshooting

• Battery voltage 18 - 32 V
• Vehicle electrical system checked in accordance with the Owner´s Manual for the vehicle and found
satisfactory.
• Fuse for retarder control unit checked and found satisfactory.
• Plug at valve block and socket checked for damage as well as wear (notch scratches).
Special tool
53.8198.10
Measuring adapter

Diagnosis / &KHFNLQJ&RQWURO&XUUHQWRI3URSRUWLRQDO9DOYH
Job scope test 21
1. Disconnect plug at proportional valve (21) and connect with measuring adapter (99/3). 98/8
2. Connect plug of measuring adapter (99/3) with the proportional valve (21).
3. Connect the Multimeter (98/8) to the measuring socket 1. Switch position: mA or A
4. Turn switch „Propvalve“ at measuring adapter (99/3) in position „I“.
5. Shift the retarder stage switch in position 5 and compare the read-off value with the given values
99/3
of the control current of the proportional valve in accordance with the tables see page 5.10/1.
FD923
99/3 Measuring adapter „Prop current“ 53.8198.10

99/8 Multimeter

Diagnosis / &KHFNLQJ7HPSHUDWXUH$GDSWLRQ
Troubleshooting

l Vehicle ignition system OFF
l Pressure gauge constant-air pressure (99/9) connected
l Vehicle electrical system checked in accordance with the Owner´s Manual for the vehicle and
found satisfactory.
Special tool
Wasser Öl
53.8207.10 53.8279.10
Temperature simulator Adapter cable

Diagnosis / &KHFNLQJ7HPSHUDWXUH$GDSWLRQ
Arbeitsumfang Prüfung 57
1. Connect temperature simulator (99/2) with adapter cable (98/5) to plug temperature simulator (57). 98/5
Note 99/2
Mind the correct connection of the plugs for cooling-water and oil!
2. Set the rotary switch of the temperature simulator (99/2) to 95°C cooling water temperature and
165°C oil temperature. Operate the retarder at the highest braking stage.
3. Set the rotary switch of the temperature simulator (99/2) to 105oC cooling water temperature. The FD1455
constant-air pressure py must drop temporary below the set maximum pressure. Set rotary switch
of the temperature simulator (99/2) to 125oC cooling water temperature. There must be no more 99/2 Temperature simulator 53.8207.10
output of constant-air pressure py. 98/5 Adapter cable 53.8279.10
Set rotary switch of temperature simulator (99/2) again to 95oC cooling water temperature.
4. Set the rotary switch of the temperature simulator (99/2) to 185oC oil temperature.rThe constant-air
pressure must drop temporary below the set maximum pressure. Set the rotary switch of the tem-
perature simulator (99/2) to 225oC oil temperature. There must be no more output of constant-air
pressure py.
5. Reconnect electrical lead (57) to temperature pick-up cooling-water and oil.

Diagnosis / &KHFNLQJ3UHVVXUH6HQVRU
Troubleshooting

• Ignition ON
• Pressure gauge constant-air pressure connected
• Retarder stage switch in position 0
Special tool
53.8198.10
Measuring adapter

Diagnosis / &KHFNLQJ3UHVVXUH6HQVRU
Job scope test

1. Disconnect plug of pressure sensor (38) and connect with measuring adapter (99/3). 98/8
2. Connect plug of measuring adapter to pressure sensor (38).
3. Connect electrical lead Ground of Multimeter (98/8) to measuring socket 4 of adapter.

38
4. Turn switch „Propvalve“ at measuring adapter (99/3) downwards (not in position „I“).
5. Connect electrical lead Positive of Multimeter to measuring socket 1.

99/3
6. The measured voltage must be between 4,75 and 5,25 V. 99-03-923a
7. Connect electrical lead Positive of Multimeter to measuring socket 2.
8. Compare measured voltage in conjunction of constant-air pressure with the following values:
0 bar = 0,3 - 0,7 V
2,5 bar = 2,8 - 3,2 V 98/8
9. After disconnecting the measuring adapter connect electrical lead again to pressure sensor.
38
99/3
99-03-923b

Diagnosis / &KHFNLQJ3XPS3UHVVXUH
Troubleshooting
Prior jobs
• Retarder stage switch in braking stage 0
• Ignition OFF
103 Screw plug (measuring point pump

pressure) M12x1,5
103
13 Nm (20 Nm)
Note
The pump pressure check provides information

on internal leaks and on the correct operation of
the retarder.
Special tool
53.4788.10
Oil pressure gauge M+P-07A-1491
0-25 bar


l Vehicle electrical system checked in accordance with the Operating Manual for the vehicle and
found satisfactory.
l Compressed-air pressure 6 - 11 bar
l No external leaks at the retarder
l Retarder stage switch in braking stage 0
Caution!



The screw plug (103) and the oil is hot! 103
103
Caution!
Easy oil-exit is caused constructively, but has no effect on the function of the retarder, however.
Job scope test
1. Screw out screw plug (103).
2. Connect up pressure gauge (99/1) to the retarder housing.
99/1
M+P-07A-1493

3. Drive the vehicle with a prop shaft speed of v ps = 1000 r.p.m.

Put in direct gear (gear ratio 1:1), and drive with an engine speed of 1000 r.p.m.
4. Shift the retarder stage switch to position 5 while on the move and read pump pressure off
test pressure gauge (99/1) at prop shaft speed vps = 1000 r.p.m.
5. Compare read-off pump pressure with the value of dynamic pump pressure according to the table
see page 5.10/1.
Caution!
If the constant-air pressure (py) is obtained in the test at stillstand (see chapter 5.5), but the minimum
value of the dynamic pump pressure is not reached, please contact your Voith service partner.
Hot oil can leave when disconnecting the presure gauge!
6. Check sealing ring of screw plug for damages; renew if necessary.
7. Disconnect pressure gauge. Screw in screw plug tight.

Tightening torque screw plug (103): 13 Nm (20 Nm).

Diagnosis / 7DEOHRI0HDVXUHPHQWV
Troubleshooting
Code number 2) Control current mA1) 3) 5) Constant-air pressure (py) Pump pressure (dynamic) 1)
(static) 4) 1) vps = 1000 r.p.m.
set value [bar] minimum value [bar]
055 396 - 596 2,10 - 2,30 17
056 - 058 409 - 609 2,30 - 2,50 19
059, 079, 080 440 - 640 2,75 - 2,95 23
1) Retarder stage switch in highest braking stage!

2) The code number is to be found on the control unit
3) If a commercially available multimeter is used for measurements (without real effective measuring)
exact readings cannot be made (indication jumps!).
4) Decisive is the pressure which has built up itself after 30 seconds (stabilized, constant pressure).
5) The values are not steadily because of continuous control in the closed loop (however within the
stated range).
Note
These values represent the state of the art at the time going to print. The manufacturer reserves the right
to make further modifications.

Diagnosis / 2SHUDWLRQDO&KHFN
Troubleshooting

• Battery voltage 18 - 32 V
• Electrical system checked in accordance with the Operating Manual for the vehicle
and found satisfactory.
• Constant-air pressure 6 -11 bar
• Retarder oil level satisfactory
The following operational states are indicated by the retarder pilot light:
Retarder pilot light without indication

The retarder is switched off. There is no fault in the memory.
Retarder pilot light permanently on

The retarder is switched on, i.e., one of the four possible retarder braking stages or
„Constant Speed“ operation has been selected with the retarder stage switch.
The retarder pilot light additionally has the function of a fault indicator.
- slight fault
Continous light in position 0 - 5 of the retarder stage switch, braking operations are possible (partly
with reduced braking torque).
- serious fault
The retarder pilot light shows permanent light in position 0 - 5 of the retarder stage switch.
There are no more braking operations possible - the retarder is switched off.

Note
If the ignition is switched off and on again, the retarder is in operation and the retarder pilot light
is going off.
If the fault occurs again, the retarder switches off again and the retarder pilot light is permanently on in
position 0 to 5 of the retarder stage switch.
Retarder pilot light flashes
- during retarder braking

The temperature adaption is effective - the retarder regulates back its braking torque.
These flash function however, is only realized at defined regulation variants!

Test step Scope of check Requirement / Result / Set point Note, Cause / Remedy
Operation
1 Retarder pilot light Ignition: ON Retarder pilot light comes on and Retarder pilot light trouble-free
goes off after approx. 5 sec.
Retarder pilot light does not come Troubleshooting as on page 5.1/2

on, or does not go off.
2 Retarder Vehicle on move Retarder pilot light comes on, Retarder operates trouble-free.
- Shift retarder stage retarder brakes in stages 1 to 5.
switch to stage 1 to 5.
Retarder pilot light does not come Troubleshooting as on page 5.1/2
on, or retarder does not brake
properly.

Gearbox Remo- 5HPRYLQJ,QVWDOOLQJ*HDUER[
ving, Installing
6.1 Removing, Installing Gearbox ....................................................................6.1/1

cbtd 00-01 53.2687.10
3RZHUWUDLQ%XVLQHVV8QLW 3URGXFWXQLWUHWDUGHU
Page 6/1
7UDQVPLVVLRQV
Gearbox, Remo- 5HPRYLQJ,QVWDOOLQJ*HDUER[
ving, Installing (Continue)
Illustration removing, installing gearbox
Prior jobs
• Ignition OFF 5 6
• Shift linkage removed
• Clutch output cylinder removed
• Engine bonnet removed, if necessary
• Engine compartment enclosed casing
removed, if necessary
• Clutch servo removed, if necessary
(chapter 8.6)
21
Weight in kg: approx.195 kg without clutch 19
housing
7 26
3 3
Achtung Verletzungsgefahr!
Secure vehicle, engine and gearbox propper!

20
1 Plug switch reversing light

3 Connecting piece 4
4 Plug speedometer sensor
5 Hex.-head nut, renew
1
6 Propeller shaft
7 Plug switch for starter lock 25/250/119
19 Plug cooling-water temperature
pick-up M+P-07A-1773
20 Plug oil temperature pick-up
21 Plug proportional valve
26 Compressed-air line supply-air
pressure Remark:
25/250/119 Hex.-head screw M10x45,
45 Nm

cbtd 00-01 53.2687.10
Page 6.1/1
7UDQVPLVVLRQV
Workshop equipment
Gearbox lifter Nr. 554
Manufacturer: e. g. Fa. Kirner

Obersteinstraße 139
D-55602 Kirn
Tel. 06752 / 93110
Fax 06752 / 71751
M+P-07A-1775

Adapter for gearbox lifter Nr. WBM 0079.06
Manufacturer: e. g. Fa. Wagner

Dieselstraße 9-11
D-70829 Gerlingen
Tel. 07156 / 22013
Fax 07156 / 22014
M+P-07A-1776
Commercially available equipments
Wheel gripper tool RG 5/2HD2 z. B. Fa. Hywema

Removing, installing
1. Lift the vehicle with 4 wheel gripper to the wished working height.
2. Drain coolant (heed the statements of the vehicle-manufacturer).
3. Drain oil of gearbox and retarder (chapter 3.4 and 3.5).
4. Prop up engine with suitable device, (heed the statements of the vehicle-manufacturer).
5. Remove eventually existing cross bars, which are in the way with the removal of the gearbox.
Note for installation

Tightening torque: 55-65 Nm
6. Remove connecting pieces (3) from heat exchanger.
7. Pull the plug (19) from cooling-water temperature pick-up.
8. Pull the plug (20) from the oil temperature pick-up.
9. Remove compressed-air line (26) from proportional valve.
10. Pull the plug (21) from proportional valve.
11. Pull the plug (1) from switch reversing light.
12. Pull the plug (4) from speedometer sensor.
13. Pull the plug (7) from switch for starter lock.

14. Remove propeller shaft (6) from retarder.
Note for installation:

Use new self-locking hex.-head nuts.
Tightening torque according to vehicle manufacturer instructions.
15. Screw out hex.-head screws from bracket / engine bearing right and left.

16. Screw out top hex.-head screw from clutch housing / engine.

17. Remove both rear engine bearing brackets.

18. Drive gearbox lifter with adapter below the gearbox, adjust gearbox lifter and secure with safety
chain.
Slightly lift the gearbox.
19. Screw out bottom hex.-head screw from clutch housing / engine.

20. Lift the gearbox higher and drive out it to the rear.

21. Clean all parts, check for wear, and renew parts if necessary.
22. Install in reverse sequence.
23. Top up coolant according to the vehicle manufacturer instructions. Heed the cooling water-quality in
chapter 11.
24. Top up oil of gearbox and retarder. Therefore heed chapter 3.4 and 3.5.
25. Enforce a visual examination on leaks after taken place test drive.
Note
Connections as hoses, hose ties, screws and nuts, plugs and terminals must be in propper conditions.
Defective parts must be renewed.
Clean the drive shaft and grease it wafer-thin. Therefore see Operating Specifications of
vehicle manufacturer.
Engage retaining ring before installation of the clutch output cylinder by pulling at the clutch release fork.
Check the function by pushing.
Check gearbox oil level: See chapters 3.2: „Checking Oil Level of Gearbox” and 3.3: „Checking Oil Level
of Retarder“.
Top up coolant: See statements of the vehicle-manufacturer.

Retarder Remo- 5HPRYLQJ,QVWDOOLQJ5HWDUGHU
ving, Installing
7.1 Removing, Installing Retarder ....................................................................7.1/1

ving, Installing
Illustration removing, installing retarder

Prior jobs 25000 25300
(26/860/020*)
• Gearbox (with retarder) removed 25300
(see chapter 6.1) 850
• Connecting pieces removed
(see chapter 9.4)
• Speedometer sensor removed 25200
(see chapter 8.5)
• Output flange removed
(see chapter 8.7)
850 Outer race

Remove only, if taper roller
bearing is renewed or a new
25100
balance washer is added 4100
(26/860/023*)
(DC-tool)
850/001 Taper roller bearing
4100 Screw plug M30x1,5
100 Nm (150 Nm)
25000 Balance washer
25100 O-ring, renew 25200
coat with silicone-free and non-
corrosive grease for installation
25200 Hex.-head screw M10x70
Hex.-head, w.a.f. 15
850/001
58 Nm
25300 Hex.-head screw M10x60 M+P-07A-1497
Hex.-head, w.a.f. 15,

58 Nm * DaimlerChrysler position number

Special tools
67.2713.10 67.3056.10 on inquiry on inquiry
Control device Measuring device Puller for Impact tool

outer race for outer race
Tool for local fabrication
15
M10
80
Material: St37-2, DIN 17100 (1.80)
0073ae
Threaded bolt M10x80

Lubricants and locking agents
O-rings Silicone-free and

Retarder housing Omnifit FD10-1042
Caution!
The measuring device 67.3056.10 has to be calibrated annually! The workshop using this device
is responsible for calibration and the propper condition of the device.

brackets are valid. The copper-sealing rings are generelly to be renew.

Service-

25200
Caution! Risk of injury! 25300
Secure retarder before working step 1 (prop up)!
Caution!
Remove speedometer sensor before working step 1 (see chapter 8.5)!
Removing, installing 25200

1. Screw out the 5 hex.-head screws (25200) and 17 hex.-head screws (25300) and remove retarder M+P-07A-1498
with suitable lifter device from gearbox.
2. Remove O-rings (25100) from gearbox.

25000
850
Note
You must execute the following working-step only, if:
- a new retarder is installed

- the taper roller bearing (850/001) is renewed or
- the gearbox is renewed
3. Dismantle outer race (850) with puller for outer race (DaimlerChrysler tool F3 6280 0 486 285) and 850/1 25100 M+P-07A-1499
remove balance washer (25000).

Installing
1. Determine the thickness of the balance washer like follows:
Note a
Determine the thickness of the balance washer only, if:
- one or both taper roller bearings of the retarder was renewed

- the retarder was dismantled or changed or
- the gearbox was dismantled or changed
M+P-07A-1444
The following described measurements may only being carried out at room temperature!
1.1 Take measuremnets of the spacing „a” between the surface of the gearbox housing (320) on
retarder side and the surface of the balance washer. Note down the measured value as
61
dimension „a“. 62 63
1.2 Place measuring device (98/1) on supporting plate (60).

60
1.3 Push vernier caliper (61) at measuring plate (62) and set to zero by using the reset key (63).
M+P-07A-1976
98/1 Measuring device 67.3056.10

1.4 Place outer race (850) on taper roller bearing (850/1).

62
1.5 Place measuring plate (62) on outer race (850) and check correct and gap-free seat by rotation.
Then press with one hand powerful onto the measuring plate (62) and turn the driving wheel (ar-
row) 2 turns clockwise and 2 turns counter-clockwise.
850
850/1
M+P-07A-1977
1.6 Place the measuring device (98/1) in the way on the retarder housing, that both plastic bolts mesh
in the flat surface.
1.7 Place vernier caliper (61) at measuring plate (62) and read-off value.
61
Note 62
98/1
The measured value must be between +0,86 mm and -0,28 mm, contact Voith if necessary.
1.8 Calculate dimension „b“.
Dimension „b“ plus or minus the read-off value from working step 1.7 (heed sign at scale). M+P-07A-1978
Note down the calculated value as dimension b.
98/1 Measuring device 67.3056.10

1.9 Place again the measuring device at the supporting plate (60).
1.10 Push vernier caliper (61) at measuring plate (60) and check, if zero position still is set.
61
62 63
Note
60
The measuring device must display zero, if necessary press reset key to repeat measuring procedure.
1.11 Calculate thickness of balance washer.

M+P-07A-1976
Thickness of balance washer = dimension „a“ minus dimension „b“ minus 0,02 mm
2. Place balance washer (25000) into gearbox housing (if dismantled).
Note 25000
850
If taper roller bearing was renewed, renew also outer race (850).
3. Place outer race (850 - if removed) into the gearbox housing and knock it in with the impact tool
for the outer race (DaimlerChrysler tool) as far as it will go.
M+P-07A-1446

4. Clean sealing surface of retarder housing (1).

1
M+P-07A-1501
5. Turn the gearbox until the sealing surface does show upwards (gearbox is in vertically position).
6. Clean sealing surface of gearbox housing and coat it with locking agent Omnifit FD10-1042. 25100
7. Coat O-rings (25100) with silicone-free and non-corrosive grease and place into the gearbox.
8. Screw in two threaded bolts M10x80 (see arrows) into the gearbox housing.
The threaded bolts are required so that the sealing surfaces (gearbox/retarder) can be installed
congruent.
M+P-07A-1448

9. Place retarder at gearbox and screw it tight with 5 hex.-head screws (25200).
25200
Tightening torque hex.-head screws 58 Nm
25200
10. Unscrew the two threaded bolts M10x80 again. 25200
11. Screw in the 17 hex.-head screws (25300) and screw them tight.
Tightening torque hex.-head screws 58 Nm
25300
M+P-07A-1502a
12. Turn gearbox with fixed retarder in the horizontally position again.
13. Screw out screw plugs (4100) out of retarder housing.
4100
M+P-07A-1497a

14. Press threaded spindle of control device (98/2) into direction of arrow as far as it will go.
98/2
4100
M+P-07A-1997
M+P-07A-1503
98/2 Control device 67.2713.10
15. Screw control device (98/2) via „A“ hand tight into the retarder housing. A
98/2
16. Screw control device (98/2) via „B“ into the drive shaft until it is turning too.
Note B
Over the threaded bore of the speedometer sensor (arrow) can be determined, if the impulse ring itself
and so the drive shaft turns.
M+P-07A-1979

17. Fix the holder (99/8) with dial gauge at retarder housing.
18. Place test prod with initial tension at surface (arrow) of control device (98/2) and set scale of 4100
dial gauge to zero.
99/8
98/2 M+P-07A-1980
M+P-07A-1503
19. Check gap of taper roller bearings as following:
0HDVXUHPHQW
19.1 Connect filling connection (arrow) with compressed-air and charge control device (98/2) with
compressed-air (approx. 6 to 8 bar).
19.2 Turn shaft of the control device (64) three times about its own axis. 98/2
19.3 Read-off the values of the dial gauge while turning shaft of the control device (64) again one time
about 360°. Make marking at surface of control device at the point you can read-off the lowest
value of the dial gauge.
19.4 Place test prod with initial tension at the marked position and set scale of dial gauge to zero. 64
M+P-07A-1981
Seite 4/1Service-Handbuch VOITH Retarder 115 E

0HDVXUHPHQW
19.5 Connect filling connection (arrow) with compressed-air and charge control device (98/2) with 4100
compressed-air (approx. 6 to 8 bar).
19.6 Turn shaft of the control device (64) three times about its own axis.
98/2
19.7 Read-off the values of the dial gauge while turning shaft of the control device (64) again one time
about 360°.
The smallest value corresponds the bearing gap.
Set value: 0,02 to 0,12 mm, contact Voith if necessary.

64
M+P-07A-1982
M+P-07A-1503
Caution!
If the set value is not reached, the retarder must be removed and be installed again with another
corresponding balance washer. To this all working steps described in this chapter must be carried out
once again.
4100
20. Remove control device again.
21. Check sealing ring of screw plug (4100) on damages; renew if necessary.
22. Screw in screw plug (4100) again and screw it tight.

Tightening torque: 100 Nm (150 Nm) M+P-07A-1497a

Repair 5HSDLU*HDUER[
Gearbox
8.1 Overall Illustration of Main Components ....................................................8.1/1

8.2 Removing, Installing Front Housing Cover, Cover Countershaft and
Closing Cover 5./6.- Gear...........................................................................8.2/1
8.3 Removing, Installing Shift...........................................................................8.3/1
8.4 Removing, Installing Breather ....................................................................8.4/1
8.5 Removing, Installing Sensor/Switch at Gearbox ........................................8.5/1
8.6 Removing, Installing Clutch Servo
and Adjusting Wear Indicator .....................................................................8.6/1
8.7 Removing, Installing Output Flange
Renewing Radial Shaft Sealing Ring .........................................................8.7/1

Repair 2YHUDOO,OOXVWUDWLRQRI0DLQ&RPSRQHQWV
Gearbox
Illustration main components gearbox GO170 - GO210
26/350/083
26/350/080
26/100/056 26/250/047
26/100/206
26/100/053
26/350/101
26/100/059 26/860/026
26/100/032
26/860/017
25/250/020 26/860/014
26/100/038
26/860/026
26/100/014
26/100/008
26/100/197
26/100/203 26/100/200
26/100/023 26/100/194
26/400/089
26/100/029 26/400/083 26/100/128
26/100/128 26/100/122
26/100/125 26/100/128
26/100/125
25/250/008 25/250/113 26/250/068 26/100/113

26/350/071
26/350/ 26/100/107 26/100/116

26/100/119
25/250/068
26/350/065
25/250/110
25/250/008 Clutch housing 26/100/122 Oil filler plug

25/250/020 Hex.-head screw 26/100/125 Oil drain plug
25/250/068 Clutch servo 26/100/128 Sealing ring
25/250/110 Cover metal sheet 26/100/194 Sealing ring
25/250/113 Hex.-head screw 26/100/197 Anti-fatigue screw
26/100/008 Front housing cover 26/100/200 O-ring
26/100/014 O-ring 26/100/203 O-ring
26/100/023 Radial shaft sealing ring 26/100/206 Speedometer sensor
26/100/029 Hex.-head screw 26/250/047 Switch starter lock *
26/100/032 Countershaft cover 26/250/068 Inductive sensor for overspeed protection *
26/100/038 Hex.-head screw 26/350/065 Hex.-head screw
26/100/053 Closing cover 5./6.-gear 26/350/071 Breather complete
26/100/056 O-ring 26/350/080 Cover bearing reverse gear end stop
26/100/059 Hex.-head screw 26/350/083 Radial shaft sealing ring
26/100/107 Oil sieve 26/350/101 Hex.-head screw
26/100/113 Spring 26/350/ Shift
26/100/116 Screw plug 26/400/083 Oil temperature pick-up gearbox *
26/100/119 Sealing ring 26/400/089 Switch reversing light *
26/860/014 Radial shaft sealing ring
26/860/017 Radial shaft sealing ring
* = option 26/860/026 Hex.-head screw

cbtd 00-01 53.2687.10
Page 8.1/1
7UDQVPLVVLRQV
Repair 5HPRYLQJ,QVWDOOLQJ)URQW+RXVLQJ&RYHU&RYHU
Gearbox &RXQWHUVKDIWDQG&ORVLQJ&RYHU*HDU (Cont.)
Prior jobs
• Gearbox removed (chapter 6.1)
• Gearbox housing removed
• Clutch servo removed (chapter 8.6)
• Clutch release removed
26/100/008 Housing cover front,

coat with sealant
Omnifit FD10-1042
26/100/056
26/100/014 O-ring, renew 26/100/053
26/100/023 Radial shaft sealing ring, renew 26/100/059
26/100/029 Hex.-head screw
30 Nm
26/100/023
26/100/032 Cover countershaft,
coat with sealant
Omnifit FD10-1042 26/100/008
26/100/038 Hex.-head screw M10x35
30 Nm
26/100/053 Closing cover 5./6.- gear
26/100/014
26/100/056 O-ring, renew
coat with silicone-free and non- 26/100/032
30 Nm 26/100/038
26/100/029
M+P-07A-1774
Remark:

Sealants and Lubricants
Runddichtringe Silicon- und

säurefreies Fett
Gehäusedeckel Vorgelegewellendeckel Omnifit FD10-1042

Verschlußdeckel 5./6.-Gang
To remove, to install
1. Only with gearbox G0210:
1.1 Screw out hex.-head screws (26/100/059).
26/100/056
1.2 Remove closing cover 5./6.-gear (26/100/053) with O-ring (26/100/056) ab. 26/100/053
Clean sealing surface.
26/100/059
Coat new O-ring (26/100/56) with silicone-free and non-corrosive grease.
Tightening torque: 30 Nm
M+P-07A-1779
Remark:

Note
Do not damage oil spin disk in front housing cover (26/100/008)! Therefore perform working step 2 to 5 26/100/008
only with gearbox in vertical positioned gearbox (drive shaft up).
2. Screw out hex.-head screw (26/100/029).
3. Remove front housing cover (26/100/008).

26/100/029
M+P-07A-1781
4. Remove O-ring (26/100/014).
5. Remove radial shaft sealing ring (26/100/023).

Install new radial shaft sealing ring (26/100/023) pin drift, thus the sealing lip shows upwards
Coat new O-ring (26/100/014) with silicone-free and non-corrosive grease.
Coat sealing surfaces of housing cover with sealant Omnifit FD10-1042.
Tightening torque: 30 Nm
26/100/023
26/100/014 M+P-07A-1778
Remark:

6. Screw out hex.-head screws (26/100/038).
7. Remove countershaft cover (26/100/032).


Coat sealing surfaces of housing cover with sealant Omnifit FD10-1042.
Tightening torque: 30 Nm 26/100/032
8. Install in reverse sequence. 26/100/038
M+P-07A-1780
Remark:

Repair 5HPRYLQJ,QVWDOOLQJ6KLIW
Gearbox
Prior jobs
• Gearbox selector rod removed
• Switch for starter lock removed
(if available)
26/350/065 Hex.-head screw M8x60

26/350/080
26/350/083
16-21 Nm
26/350/080 Bearing cover of reverse gear
end stop, coat with sealant
Omnifit FD10-1040 26/350/101
26/350/083 Radial shaft sealing ring, renew
16-21 Nm
26/350/x Shift, coat with sealant
Omnifit FD10-1040
Sealant
Cover bearing of Omnifit FD10-1042

reverse gear end stop,
shift 26/350/x
26/350/65
M+P-07A-1777
Remark:

Repair 5HPRYLQJ,QVWDOOLQJ6KLIW
Gearbox (Continue)
1. Switch gearbox in neutral position.
3. Remove bearing cover reverse gear end stop (26/350/080).
4. Remove radial shaft sealing ring (26/350/083).

Knock in new radial shaft sealing ring with suitable pin drift.
Coat sealing surface of bearing cover reverse gear end stop with sealant Omnifit FD10-1042.
6. Remove shift (26/350/X).

Coat sealing surface of shift with sealant Omnifit FD10-1042.

Repair 5HPRYLQJ,QVWDOOLQJ%UHDWKHU
Gearbox
Prior jobs
1
• Engine compartment enclosed casing removed, if necessary 2
26/350/071 3
26/350/071 Breather complete
1 Hex.-head screw 20 Nm 4
2 Spring washer 5
3 Bush
4 Oil sieve
5 Neck
M+P-07A-1782
Remark:

Repair 5HPRYLQJ,QVWDOOLQJ6HQVRU6ZLWFKDW*HDUER[
Gearbox
Prior jobs
26/100/89 Switch reverse gear * 26/250/047

40-52 Nm
26/100/206 Speedometer sensor
32-42 Nm
26/250/68 Induktive sensor for overspeed
protection *
26/400/83 Oil temperature pick-up gearbox *
40Nm
* = option
26/100/206
26/100/089
26/250/068
26/400/083
M+P-07A-1772
Remark:

Repair 5HPRYLQJ,QVWDOOLQJ&OXWFK6HUYRDQG
Gearbox $GMXVWLQJ:HDU,QGLFDWRU
Prior jobs
25/250/068 Clutch servo

25/250/113 Hex.-head screw, 40 Nm
35 Tappet
25/250/110 Cover metal sheet
38 Spacer
39 Neck
40 Sealing rings, renew
41 Compressed-air pressure line
42 Hydraulic pipe
43 Banjo bolt 25/250/113
44 Closing cover
45 Banjo bolt 38
39 42
45
40 44
41
25/250/068
40 43
35 25/250/110
M+P-07A-1798
Remark:

Gearbox $GMXVWLQJ:HDU,QGLFDWRU(Continue)
To remove
1. Remove compressed-air pressure line (41) and hydraulic pipe (42) from clutch servo.
42
41
M+P-07A-1799
2. Screw out hex.-head screws (25/250/113) and remove clutch servo (25/250/068) with the cover 25/250/068
metal sheet (25/250/110).
25/250/113
M+P-07A-1800
Remark:

To install
1. Snap in by hand the clutch release bearing, with the help of the clutch release fork (arrow), through
the opening of the clutch housing into the stress ring of the clutch.
M+P-07A-1801
2. Align clutch servo (25/250/068) with cover metal sheet (25/250/110) at clutch dome. 25/250/068
3. Screw the hex.-head screws (25/250/113) tight.
Tightening torque: 40 Nm.
25/250/113
M+P-07A-1800
Remark:

4. Install compressed-air pressure line (41) with banjo bvolt (43) and new sealing ring (40)
to clutch servo (25/250/71).
42
5. Install hydraulic pipe (42) with spacer (38), neck (39), banjo bolt (45) and closing cover (44) to
clutch servo (37). 44 45 39 38
6. Bleed hydraulically clutch actuation.

43
40
41
25/250/71 M+P-07A-1803
Remark:
Adjust mechanical wear indicator:
7.1 Pull cover cap (54) off.

51 52 53 54
7.2 Release hex.-head nut (52).
7.3 Screw in wear indicator (53) as far as the indicator (51) is flush with the wear indicator (arrow).
7.4 Fit cover cap (54).
M+P-07A-1804

8. Wear control:
8.1 Pull cover cap (54) off.

54
8.2 Check wear of clutch disk.
Note
The clutch disk is wear out, if the back edge of the indicator (51) is flush with the back edge of the 51
wear indicator (arrow).
M+P-07A-1805
8.3 Fit cover cap (54).

Repair 5HPRYLQJ,QVWDOOLQJ2XWSXW)ODQJH
Gearbox 5HQHZLQJ5DGLDO6KDIW6HDOLQJ5LQJ
Prior jobs
31
removed, if necessary 26/100/197
26/860/014 Radial shaft sealing ring, renew 32

26/860/017 Radial shaft sealing ring, renew
corrosive grease for installation 26/100/194
26/100/197 Anti-fatigue screw, renew 26/100/203
450 Nm
corrosive grease for installation 26/860/014
31 Hex.-head nut, renew
32 Propeller shaft
Lubricants
O-ring Silicone-free and

non-corrosive grease M+P-07A-1797
Remark:

Repair 5HPRYLQJ,QVWDOOLQJ2XWSXW)ODQJH
Gearbox 5HQHZLQJ5DGLDO6KDIW6HDOLQJ5LQJ(Continue)
1. Remove propeller shaft from output flange.

Use new self-locking hex.-head nut (31).
Tightening torque according to vehicle manufacturer instructions.
2. Screw out anti-fatigue screw (26/100/197) and remove O-rings (26/100/194), (26/100/200)
and 100/203).

Coat new O-rings (26/100/200 und 26/100/203) with silicone-free and non-corrosive grease and
use new anti-fatigue screw.
Tightening torque: 396 - 484 Nm.
3. Pull off output flange.
4. Remove radial shaft sealing rings (26/860/014 and 26/860/017).

Install new radial shaft sealing rings (26/860/014 and 26/860/017) with suitable pin drift.

Repair 5HSDLU5HWDUGHU
Retarder
9.1 Overall Illustration of Main Components ....................................................9.1/1
9.2 Removing, Checking and Installing Casing Ventilation ..............................9.2/1
9.3 Removing, Cleaning and Installing Silencer...............................................9.3/1
9.4 Removing, Installing Water Neck ...............................................................9.4/1
9.5 Removing, Checking and Installing Heat Exchanger .................................9.5/1
9.6 Removing, Installing Oil Tank Cover ..........................................................9.6/1

A Top Oil Tank Cover ......................................................................................9.6/1
B Bottom Oil Tank Cover .................................................................................9.6/2

Repair 2YHUDOO,OOXVWUDWLRQRI0DLQ&RPSRQHQWV
Retarder
Illustration main components R 115 E
6101 3300
6100 4100
6101 3100
9000
3300 3850 2000/1
3850
2800/1 3800 3900

8000
6600
6700 4000
3700 5400
2900 2300 5500
5600
7500
2301
25000
109
850
6400
7300 20100
5200 7600 20000
20300
5300
7500 20200
103 7300 20300
2600
3500 6700
5200
2500/1 6600
5300
20000
3100 4100 20100
20200
107 6700
4200 4200
6600 20300
M+P-07A-1504b
103 Screw plug M12x1,5, Inhex.-head, w.a.f. 6 5300 Sealing ring A14x20
107 Screw plug M24x1,5, Inhex.-head, w.a.f. 12 5400 Corrugated spring
109 Screw plug M24x1,5, Inhex.-head, w.a.f. 12 5500 Disc (silencer) D30x4
850 Outer race 5600 Circlip
2000/1 Top cover 6100 Pipe
2300 Casing ventilation Bgr. D30x38, die casting 6101 O-ring 15,3x2,4
2301 O-ring 55x3 6400 Heat exchanger
2500/1 Bottom cover 6600 Hex.-head screw M14x40, w.a.f. 19
2600 Bottom gasket alternative: hex.-head screw with flange M14x40
2800/1 Cover casing ventilation Bgr. 6700 Washer
2900 Gasket 7200 Throttle disc 39/15x3
3100 Combined hex.-head screw M8x30, w.a.f. 13 7300 O-ring 15x4
3300 Combined hex.-head screw M8x30, w.a.f. 13 7400 O-ring 40x2
3500 Screw plug with sieve, M30x1,5, 7500 O-ring 45x5
Inhex.-head, w.a.f. 17 7600 O-ring 25x4
3700 Proportional valve 7800 O-ring 34x3
3800 Damping plate 8000 Intermediate plate 196x144x2
3850 O-ring 16x3 9000 Pressure sensor 0-4 bar
3900 Combined hex.-head screw M8x20, w.a.f. 13 20000 Water neck
4000 Hex.-head nut M8 20200 Combined hex.-head screw M8x80, w.a.f. 13
4100 Screw plug M30x1,5, Inhex.-head, w.a.f. 17 20300 Hex.-head screw M14x1,5, w.a.f. 6
4200 Screw plug M24x1,5, Inhex.-head, w.a.f. 12 25000 Shim (selection row)
5200 Temperature pick-up

Repair 5HPRYLQJ&KHFNLQJDQG,QVWDOOLQJ
Retarder &DVLQJ9HQWLODWLRQ
Illustration casing ventilation
Note
This step can be performed with the retarder removed or installed.
Prior jobs
• Ignition OFF
• Retarder OFF
• Proportional valve and damping plate removed (chapter 10.1)
The retarder housing is hot!

Retarder &DVLQJ9HQWLODWLRQ(Continue)
2300 Casing ventilation D30x38

2300/1 Valve insert
2300/2 Float 3300
specified weight 11g ± 1 g
2300/3 Float cage 6101
2301 O-ring 55x3, renew,
coat with silicone-free and non- 6100
corrosive grease for installation 2800/1
2800/1 Cover casing ventilation 6101
2900 Gasket casing ventilation,
renew 2900
renew, 25 Nm
2300/1
6100 Pipe
6101 O-ring 15,2x2,4, renew
coat with silicone-free and non- 2300 2301
2300/2
Lubricants and sealing agents

2300/3
O-ring silicone-free and non-corro-

sive grease
Float Methylated Spirit
M+P-07A-1505

Special tools Tool for local fabrication
40,5 mm
7 mm
60 mm
53.9428.10 Material: St 37
53.7712.10
Weight 0,085 kg M+P-07A-1758 a
Note
The test ring can also be ordered from Voith Turbo - Voith code number 67.2757.10.

To remove
1. Screw out hex.-head screws (3300).
3300
M+P-07A-1506
2. Remove cover (2800/1) with gasket (2900) from retarder housing.

2800/1
2900
M+P-07A-1507

3. Remove pipe (6100) and O-rings (6101). 6101
6100
6101
M+P-07A-1508
4. Use the impact tool (99/5) and adapter (98/9) to extract the valve insert of the retarder housing (1).
99/5
1
98/9
M+P-07A-1509
99/5 Impact tool 53.7712.10

5. Take float (2300/2) and float cage (2300/3) out of the retarder housing (1).
2300/2
1
2300/3
M+P-07A-1510
6. Lever O-ring (2301) out of the groove of valve isert (2300/1) and pull it off.
2300/1
2301
M+P-07A-1020

To check
1. Check the float (2300/2) for damages to the surface and sealing surface (arrow).
2. Weight the float (2300/2).

2300/2
Specified weight 11 g ± 1 g. If the weight is more than the specified weight renew complete casing 2300/2
ventilation.
Note
Oil has penetrated into the float, the retarder is impaired in its operation.
FD194
FD194
3. Check sealing edge of shaft sealing ring (arrow) in the valve insert (2300/1). Put down the valve
insert (2300/1) on the float (2300/2) than weigh down the valve insert with the test ring (99/7).
Fill up the hollow space between float and upper edge of valve insert with methylated spirit. If the
sealing edge is not damaged, the fluid level must not alter in the course of 1 minute. 99/7
If necessary, renew the complete casing ventilation. 2300/2
2300/1
M+P-07A-1730

To install
1. Coat a new O-ring (2301) with silicone-free and non-corrosive grease and pull it on to the
valve insert (2300/1).
99/5
1
2. Insert the float (2300/2) and float cage (2300/3) into the valve seat.
3. Insert the casing ventilation into the retarder housing. 98/9

4. Use the impact puller (99/5) and adapter (98/9) to knock in the casing ventilation (2300).
M+P-07A-1509
99/5 Impact tool 53.7712.10

98/9 Adapter 53.9428.10
5. Put pipe (6100) with new O-rings in cover (2000).

2000
6100
M+P-07A-1511

6. Place cover (2800/1) with new gasket into air-pipe (6100) on the retarder housing and screw the
hex.-head screws (3300) tight.
Tightening torque hex.-head screws: 25 Nm.
6100
3300
2800/1
M+P-07A-1512

Repair 5HPRYLQJ&OHDQLQJDQG,QVWDOOLQJ6LOHQFHU
Retarder
Illustration Silencer
Note 5400
This step can be performed with the retarder 5500
removed or in situ.
5600
5400 Corrugated spring
5500 Disc (Silencer) D30x4,
clean with suitable cleaning agent
(Benzine) and blast out with
compressed-air
5600 Circlip JL30x1,2
konvex side must face the silencer
Cleaning agents
Silencer Benzine
M+P-07A-1456

Repair 5HPRYLQJDQG,QVWDOOLQJ:DWHU1HFN
Retarder
Prior jobs
• Ignition OFF
• Retarder OFF
• Cooling-water drained
20000 Water neck

20100 Gasket, renew
20200 Hex.-head screw M8x80 20100
Hex.-head, w.a.f. 13 20000
28 Nm
20300 Hex.-head screw M14x1,5
20200
Inhex head, w.a.f. 6
28 Nm
20100
20000
20200
M+P-07A-1568

Retarder +HDW([FKDQJHU
Illustration heat exchanger
6700
7500
6600
7300
7600
6400
7500 6700
7300 6600
4200 4200
107
M+P-07A-1513
Note
The heat exchanger can also be removed with installed retarder.
Prior jobs
• Ignition OFF
• Retarder removed (see chapter 7.1)
With retarder installed:

• Proportional valve and damping plate removed (see chapter 10.1)
• Oil drained from retarder (see chapter 3.4)
• Water neck removed (see chapter 9.4)
107 Oil-drain plug retarder M24x1,5, 6700 Washer, renew

Inhex.-head, w.a.f. 12, 65 Nm (80 Nm) 7300 O-ring 15x4, renew
4200 Oil-drain plug oil tank M24x1,5, coat with silicone-free and non-corrosive grease for installation
Inhex.-head, w.a.f. 12, 65 Nm (80 Nm) 7500 O-ring 45x5, renew
6400 Heat exchanger coat with silicone-free and non-corrosive grease for installation
6600 Hex.-head screw M14x40, w.a.f. 19, renew 7600 O-ring 25x4, renew
Initial torque: 35 Nm coat with silicone-free and non-corrosive grease for installation
Final turn: 30° turn
alternative: hex.-head screw M14x40 with flange,
w.a.f. 19, renew
Lubricant
O-ring Silicone-free and


cbtd 00-01 53.2687.10
Page 9.5/1
7UDQVPLVVLRQV
Retarder +HDW([FKDQJHU(Continue)
Caution!
Two versions of screw plugs (107, 4200) are possible:

The integrated sealing rings must be checked for possible damages during the installation of the heat
exchanger; replace complete screw plug if necessary.
brackets are valid. The copper-sealing rings are generally to be renew.

Special tool
67.1948.10
Pressure-test equipment
Turning angle measuring tool 3/4“ e.g. Messrs Richard Abr. Herder
Post box 10 08 67
D-42659 Solingen
Tel. 0212/ 888-0
Ordering No. 8200-02

Note
If this job sequence is performed with the retarder in situ, the following prior jobs must be performed:
1. Screw out oil-drain plugs (107 and 4200) as well as the oil filler plug (for quicker drain) and drain oil.
107
2. Pull cooling-water hoses off the heat exchanger.
4200 4200
M+P-07A-1489

To remove
1. Screw out the four hex.-head screws (6600).
6400
2. Remove heat exchanger (6400).
6600
6600
6600 M+P-07A-1514
3. Remove O-rings (7300, 7500 and 7600).
7500
7300
7300
7600
7500
7300
M+P-07A-1515

To check
1. Fit pressure-test equipment (99/6) together with O-rings to heat exchanger (6400) and connect 99/6 6400
compressed-air line to bottom connection (arrow).
2. Fill heat exchanger (6400) on water side with hot water (approx. 70 oC).
3. Slowly pressurize the heat exchanger (6400) from 0 to max. 10 bar overpressure (oil section of the
heat exchanger).
Note
M+P-07A-1580
If air bubbles form in the hot water or has outer leaks, the heat exchanger must be renewed.
99/6 Pressure-test equipment 67.1948.10
4. Connect compressed-air line to top connection (arrow).

99/6 6400
5. Slowly pressurize the heat exchanger (6400) from 0 to max. 10 bar overpressure (oil section of the
heat exchanger).
Note
If air bubbles form in the hot water, the heat exchanger leaks and must be renewed.
New heat exchanger are wetted with corrosion-inhibiting oil in the water- and oil section of the heat
exchanger.
Prior to installing a new heat exchanger, drain any corrosion-inhibiting oil which may have collected and M+P-07A-1581
flush it out with hot water in the water section of the heat exchanger.
99/6 Pressure-test equipment 67.1498.10

Einbauen
1. Fit new O-rings (7300, 7500 and 7600) in the bores. 7600
7500
2. Align heat exchanger (6400) with retarder housing and screw the hex.-head screws (6600) tight.
Initial torque: 35 Nm 7300

Final turn: 30° turn
7300
7500
7300
M+P-07A-1516
6600
6600
2400
6600
6600
M+P-07A-1517

3. Install the retarder, if necessary (see chapter 7: „Removing, Installing Retarder“).
4. If available, open the check valves in the flow and return pipe of the cooling-water section. Fill in
cooling-water and bleed cooling-water circuit.
Caution!
If the heat exchanger leaks, there is water present in the retarder. If the retarder is filled up, a mixture of
oil and water is created, causing the oil in the retarder to foam and escape through the casing ventilation
system to the atmosphere. For this reason, it is indispensible to flush out the retarder after repair!
While flushing, apply the brake gently several times to prevent the retarder oil warming up excessively.
5. Flush the retarder, if the heat exchanger has leaked:
To flush the retarder, fill it with 7,0 litres of engine- or flushing oil. Apply the brakes gently several times
to flush out the retarder system and drain the oil through the oil drain plugs (107 and 4200).
Repeat the procedure 2 or 3 times.
- Check sealing rings of oil-drain plugs for possible damages; renew oil-drain plug if necessary.
107
4200 4200
M+P-07A-1489

- Screw oil-drain plug tight

Tightening torque oil-drain plug (107, 4200): 65 Nm (80)
- Fill in retarder oil (chapter 3.5)
6. If heat exchanger had been leaking, deoil cooling- and heating system of vehicle according to the
vehicle manufacturer instructions.

Repair 5HPRYLQJDQG,QVWDOOLQJ2LO7DQN&RYHU
Retarder
A Top oil tank cover

Prior jobs
6101
• Ignition OFF
6100 3300 9000
• Retarder OFF
6101
Note
3100
This job sequence can also be performed with
the retarder installed.
2000/1
The retarder housing is hot! 8000

2000/1 Top cover
renew, 25 Nm
renew, 25 Nm
6100 Pipe
M+P-07A-1518
6101 O-ring 15,2x2,4, renew
8000 Intermediate plate
9000 Pressure sensor

Retarder (Continue)
Illustration oil tank cover

B Bottom oil tank cover
Prior jobs
• Ignition OFF
• Retarder OFF
• Retarder oil drained (see chapter 3.4)
2500/1 Bottom cover

2600 Bottom gasket, renew
renew, heed tightening sequence!
25 Nm
4200 Oil drain plug oil tank M24x1,5
Inhex.-head, w.a.f. 12 2600
65 Nm (80 Nm)
2500/1
3100
4200 M+P-07A-1519

Retarder (Continue)
Caution!

The integrated sealing ring must be checked during for possible damages during the installation of the
oil tank cover; replace complete screw plug if necessary.
brackets are valid. The copper-sealing rings are generally to be renew.

Retarder (Continue)
Heed the mounting position of the gasket and the cover.

Tighten all hex.-head screws in defined sequence from 1 to 17 initially with 14 - 19 Nm torque. 6
Then tighten in the same sequence with 25 Nm torque.
5 7
4 3 8
17 2 1 9
16 10
15 11
14 12
13
M+P-07A-1368

Control Parts &RQWURO3DUWV5HWDUGHU
Retarder
10.1 Removing, Installing Proportional Valve...................................................10.1
10.2 Removing, Installing Oil Temperature Pick-Up ........................................10.2
10.3 Removing, Installing Cooling-Water Temperatur Pick-Up........................10.3
10.4 Removing, Installing Pressure Sensor .....................................................10.4

Control Parts 5HPRYLQJ,QVWDOOLQJ3URSRUWLRQDO9DOYH
Retarder
Illustration proportional valve

Removing, installing proportional valve 3850
Prior jobs
• Ignition OFF
• Retarder OFF
• Supply-air discharged
• Plug at proportional valve and socket
3800 3850
checked for damages as well as wear
(notch scratches)
3900
4000
26 Constant-air pressure line pv
39 Electrical lead 39
3800 Damping plate, renew if necessary
3850 O-ring 16x3, renew
3900 Hex.-head screw M8x20 3900
Hex.-head, w.a.f. 13 3700
renew, 30 Nm
4000 Hex.-head nut M8, renew,
4000
26
18 Nm
Caution!
If, during repair work the hex.-head nuts (4000)

or the hex.-head screws (3900) have to be
unscrewed the antivibration plate also has to be
checked on mechanical and aging damages
and to be renewed, if necessary.

Control Parts 5HPRYLQJDQG,QVWDOOLQJ&RROLQJ:DWHU
Retarder 7HPSHUDWXUH3LFN8S
Removing, installing cooling-water

temperature pick-up
Prior jobs
• Ignition OFF
• Retarder OFF
5200 Cooling-water temperature pick-up,

28 Nm
5300 Sealing ring A14x20, renew 5200
5300
The coolant is hot!
Note
Please, bear in mind to the instructions

regarding the quality of coolant given from the
vehicle manufacturer or Voith Turbo.
M+P-07A-1569

Control Parts 5HPRYLQJDQG,QVWDOOLQJ
Retarder 2LO7HPSHUDWXUH3LFN8S
Prior jobs
• Ignition OFF
• Retarder OFF
32 Electrical lead
5200 Oil temperature pick-up, 28 Nm
5300 Sealing ring A14x20, renew
5300
5200
32
M+P-07A-1495

Control Parts 5HPRYLQJDQG,QVWDOOLQJ3UHVVXUH6HQVRU
Retarder
Prior jobs
• Ignition OFF
• Retarder OFF 9000
9000 Pressure sensor, 30 Nm
M+P-07A-1496

Annex $QQH[
Data Sheet: - Gearbox / Retarder
Conversion Tables
Operating Specifications: - Oil Specifications Gearbox
- Oil Specifications Retarder
- Cooling Water Quality
Spare Parts Lists
Other Information

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Annex 'DWD6KHHW
GO170-6 – R 115 E GO190-6 – R 115 E GO210-6 – R 115 E
Gearbox input power

up to [kW] 320
max. input torque [Nm]

(Standard value depending on
respective use) 1750 1900 2100
Ratio range /
expanded scale 8,17 - 1,00 6,53 - 0,80
8,17 8,16
Braking torque up to [Nm] /

Braking power up to [kW] 3750 / 700
Permissible vehicle cross weight

[t] W W

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(Continue)
Ratio GO170-6 – R 115 E GO190-6 – R 115 E GO210-6 – R 115 E
1. gear 8,170 8,170 6,528
2. gear 4,650 4,650 3,711
3. gear 2,790 2,790 2,231
4. gear 1,810 1,810 1,443
5. gear 1,250 1,250 1,000
6. gear 1,000 1,000 0,799
Reverse-gear 7,683 7,683 6,136

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D GB USA D GB USA
-37 °C - 34,6 °F -34,6 °F 18 Nm 12.6 lbf-ft 12.6 lbf-ft
-45 °C -49 °F -49 °F 19 Nm 13.3 lbf-ft 13.3 lbf-ft
10 oC 50 oF 50 oF 20 Nm 14 lbf-ft 14 lbf-ft
20 oC 68 oF 68 oF 21 Nm 14.7 lbf-ft 14.7 lbf-ft
165 °C 329 °F 329 °F 39 Nm 27.3 lbf-ft 27.3 lbf-ft
13 Nm 9.1 lbf-ft 9.1 lbf-ft 45 Nm 31.5 lbf-ft 31.5 lbf-ft

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D GB USA D GB USA
52 Nm 36.4 lbf-ft 36.4 lbf-ft 2100 Nm 1,470 lbf-ft 1,470 lbf-ft
55 Nm 38.5 lbf-ft 38.5 lbf-ft 3750 Nm 2,625 lbf-ft 2,625 lbf-ft
58 Nm 40.6 lbf-ft 40.6 lbf-ft 2,10 bar 30.45 psi 30.45 psi
60 Nm 42 lbf-ft 42 lbf-ft 2,30 bar 33.35 psi 33.35 psi
65 Nm 45.5 lbf-ft 45.5 lbf-ft 2,50 bar 36.25 psi 36.25 psi
150 Nm 105 lbf-ft 105 lbf-ft 4 bar 58 psi 58 psi
165 Nm 115.5 lbf-ft 115.5 lbf-ft 6 bar 87 psi 87 psi
180 Nm 126 lbf-ft 126 lbf-ft 8 bar 116 psi 116 psi
195 Nm 136.5 lbf-ft 136.5 lbf-ft 11 bar 159.5 psi 159.5 psi
210 Nm 147 lbf-ft 147 lbf-ft 17 bar 246.5 psi 246.5 psi
450 Nm 315 lbf-ft 315 lbf-ft 19 bar 275.5 psi 275.5 psi
1750 Nm 1,225 lbf-ft 1,225 lbf-ft 23 bar 333.5 psi 333.5 psi
1900 Nm 1,330 lbf-ft 1,330 lbf-ft 25 bar 362.5 psi 362.5 psi

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D GB USA D GB USA
7 litre 1.54 gal 1.85 gal 50.000 km 31,070 miles 31,070 miles
7,8 litre 1.72 gal 2.06 gal 60.000 km 37,284 miles 37,284 miles
12,5 litre 2.75 gal 3.30 gal 90.000 km 55,926 miles 55,926 miles
13 litre 2.86 gal 3.43 gal 100.000 km 62,140 miles 62,140 miles
135.000 km 83,889 miles 83,889 miles
1g 15.4 grains 15.4 grains 180.000 km 111,852 miles 111,852 miles
11 g 169.4 grains 169.4 grains 300.000 km 186,420 miles 186,420 miles
195 Kg 430 pounds 430 pounds 50 Km/h 31 miles/h 31 miles/h
0,02 mm 0.0008 inch 0.0008 inch
0,12 mm 0.0048 inch 0.0048 inch
0,28 mm 0.0112 inch 0.0112 inch
0,86 mm 0.0344 inch 0.0344 inch
131,31 mm 5.2524 inch 5.2524 inch

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Operating specification Mineral oil for use in gearbox:

SAE 80, 80W, 80W/85W
Type of oil Supplier

Caution! Risk of poisoning!
Addinol Gear Oil GS Addinol Mineralöl, Krumpa
Fuels are harmful to health! Agip Rotra Hy DB Agip Petroli, Rom/Italien
If a fuel was swallowed, visit immediately a doctor!
Antar EP Elf Lubrifiants, Paris/Frankreich
Keep fuels away of children!
Aral-Gear Oil EP Aral Lubricants, Bochum
Armorine,
Armorine BM
Lanester Cedex/ Frankreich
Aseol Gepress 11-508 Shell Aseal, Bern/Schweiz
Autol Gear Oil D8 Agip Schmiertechnik, Würzburg
Avia Gear Oil MZ Avia Mineralöl, München
Emil Finke Mineralölwerk,
Aviaricon Gold MZ
Bremen
BayWa Multi Purpose Gear BayWa, München
Oil
BP Oil International,
BP Energear EP
London/England
BP Energear FE GL4
London/England
BP Gear Oil EP
London/England
Calpam Multi Purpose Calpam Mineralöl-Gesellschaft,
Gear Oil Aschaffenburg

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Mineral oil for use in gearbox:

SAE 80, 80W, 80W/85W
Type of oil Supplier Fina Pontonic N Fina Europe, Brüssel/Belgien
Caltez Universal Gear Oil Caltez (UK) Limited,
Frontol Gear Oil MZ M BP Schmierstoff, Hamburg
HD London/England
Fuchs Mineralölwerke,
MOL Hungarian Oil and Gas Fuchs Titan Gear MP
Carrier Hykomol Mannheim
Co., Kornárom/Ungarn
Petroleos de Portugal, Petrogal,
Castrol EP Castrol, Swindon/England Galp Transoil
Lissabon/Portugal
Condat,
Condat Gear A Texaco Services (Europe),
Chasse-sur Rhône/Frankreich Geartex EP-A
Brüssel/Belgien
Repso Distribución, Madrid/
CS 80 M-EP Gulf Gear Lubricant (EP) SAEL, Madrid/Spanien
Spanien
Gulf Oil (GB), Cheltenham/
Deagear EP-A DEA Mineralöl, Hamburg Gulf Ultragear 4000 (GB)
England
Dearon EP-A DEA Mineralöl, Hamburg
H.o.B.- Gear Oil ML H. o.B. Burrenkopf, Köln
Deutz Öl GO-MP Klöckner Energiehandel, Köln
Hafa MPB Hafa, Paris/Frankreich
Divinal Zeller+Gmelin, Eislingen
Homberg Gear Oil MZ J. & A. Homberg, Wuppertal
Multi Purpose Gear Oil
Hyperol Multi Purpose Hyperol Mineralöl-Vertrieb,
Ssang Yong Oil Refining,
Dragon Gear TM Gear Oil Stuttgart
Seoul/Rep. Korea
Igol Trans EPA Igol France, Paris/Frankreich
Ellmo-Multi Purpose Gear Eller-Montan-Comp., Duisburg
Oil INA Rafinerija Zagreb,
Ina Transmol DB
Zagreb/Kroatien
Engen Petroleum,
Engen Gearlube HP
Kapstadt/Südafrika IP Pontiax DB Italiana Petroli, Genua/Italien
Ertoil Transmissiones F Ertoil, Madrid/Spanien Kompressol Multi Purpose Kompressol-Öl, Köln
Gear Oil
Esso Gear Oil GP-D Esso, Hamburg

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SAE 80, 80W, 80W/85W

Pennasol Multi Purpose Mineralöl-Raffinerie Dollbergen
Leprinzol SP Leprince & Siveke, Herford Gear Oil GL4
Mac MP-Gear Oil Deutsche Shell, Hamburg Petrol Transol GL4 Petrol d. d., Ljubljana/Slowenien
megol Multi Purpose Gear Meguin, Saarlouis Petramin Lubricating Oil,
Petramin Gear Oil MB
Oil GL4 Jeddah/Saudi-Arabien
MHG-Manual-Gear Oil EP MHG, Sulzbach-Rosenberg Kuwait Petroleum,
Q8 T 35
Hoogvliet RT/Niederlande
Mobilube GX-A Mobil Schmierstoff, Hamburg
Raloy Lubricantes,
Motorex Gear Oil EP Bucher, Langenthal/Schweiz Raloy Transmission EP
Santiago Tianguistenco/Mexico
Neste Oy Lubrication,
Neste Gear EP Ryazan Oil Refinery,
Espoo/Finnland Rexol MBG
Ryazan/Rußland
Oest Multi Purpose Gear Oest Mineralölwerke,
Rored EPA Pertamina, Jakarta/Indonesien
Oil Freudenstadt
Selectol Multi Purpose Käppler, Stuttgart
OMV Gear Oil MP OMV, Wien/Österreich
Gear Oil
Optimol Multi Purpose Optimol Ölwerke Industrie
Shell International, London/
Gear Oil GmbH, München Shell Spirax MA
England
Orly International,
Orly XP Luna Sonolgear DBM Sonol Israel, Haifa/Israel
Vieux-Thann/Frankreich
Bharat Petroleum Carpn.,
Petrol Ofisi, Spirol XEP
P. O. Keban EP MB Bombay/Indien
Bakanlikar-Ankara/Türkei
De Oliebron,
Panolin EP Gear GL4 Panolin, Madetswill/Schweiz Tor Multi Purpose Gear Oil
Zwijndrecht/Niederlande
Parnas/Saksan,
Parnas Parnalube GP Total EP Total Deutschland, Düsseldorf
Athen/Griechenland

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SAE 80, 80W, 80W/85W Type of oil Supplier
Ginouves Georges
York 791
Type of oil Supplier La Farlède/Frankreich
Tranself EP Elf Lubrifiants, Paris/Frankreich Zenex Gear Oil ZP Zenex Oil, Rivonia/Südafrika
Triathlon Gear Würth, Künzelsau
Unil EP Unil Deutschland, Bremen
Unil-Opal, Rueil-Malmaison/
Unil Opal Gear EP
Frankreich
Valvoline International Europe,
Valvoline X-18
Dardrecht/Niederlande Synthetic oil for use in gearbox:
Veba Movara EP-Gear Oil Veba Öl, Gelsenkirchen
Veedol International, Type of oil Supplier
Veedol Multigear
Swindon/England MB 235.11 Manual Gear Oil DaimlerChrysler AG, Stuttgart
Westfalen Grado Gear Oil Westfalen AG, Münster A 001 989 2803
Wintershall Wiolin Multi Schmierstoffraffinerie Veedol Synmesh-AT Burmah Oil Technology

Purpose Gear Oil Salzbergen Castrol Syntrans-AT Burmah Oil Technology
Westfalen Grado Gear Oil Westfalen AG, Münster Deagear Synth DEA Mineralöl GmbH
Wisura GL Wisura Mineralölwerk, Bremen
WLZ-Raiffeisen Multi WLZ-Raiffeisen, Stuttgart
Purpose Gear Oil

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The type of oil admitted for the retarder operation must meet the following specifications:
Classification group Identification Viskosity class to Performance

letters DIN 51511 class
to DIN 51502
Single-grade- HD SAE 10W API - CC/SF

mineral oil 1) SAE 20W 20 and higher
SAE 30
Synthetic oil/ HC SAE 0W40 API - CC/SF
part-synthetic oil 1) SAE 5W30 and higher
SAE 5W40
SAE 5W50
SAE10W30
SAE10W40
Synthetic oil 2) HC SAE 75W-80W see page 11/13
1) The statements of the vehicle-manufacturer are valid respecting the choice of oil types.
If no statements are available, the oils documented on the following pages are to be used.
2) Here is only allowed to use the synthetic oil documented on page 11/13.

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Mineral oil for use in retarder:

SAE 10W, 20W 20, 30

Fina Kappa Super Fina
Agip Diesel Sigma S Agip
Fina Kappa TC Fina
Agip Engine oil HD Agip
SAE 30 Serie III Krafft
Aral Basic Turboral Aral
Mobil Delvac 1300-Serie Mobil Oil
Avia Special HDC Avia
Extra Motorex
Avia Engine Oil HD Avia
Cobra Motorex
BP Vanellus C3 BP
Multimiles R/5 mono Multimiles
Castrol CRD-DB Burmah Oil
Repsol Serie 3 SAE 10W Repsol
DEA Cronus Super DEA
Repsol Serie 3 SAE 30 Repsol
DEA Rigis DEA
CS Mizar Serie 3 SAE 10W Repsol
Elf Performance XC Elf
CS Mizar Serie 3 SAE30 Repsol
Elf Performance XR Elf
CS Mizar HD SAE 20W Repsol
Elf Performance 3D Elf
Shell Rimula X Monograde Shell
Elf Performance Super D Elf
Shell Rotella MX Shell
Essolube X 301 Esso
Glap Diesel Sofomil
Essolube X 201 Esso
Glap Orion Sofomil
Wintershall Rekord 10W SRS

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Mineral oil for use in retarder: Synth./part-synth. oil for use in retarder:
SAE 10W, 20W 20, 30 SAE 0W40, 5W30, 5W40, 5W50, 10W30, 10W40
Type of oil Supplier Type of oil Supplier

Wintershall Rekord 20W-20 SRS Agip Diesel Sigma TFE Agip
Wintershall Rekord 30 SRS Agip Sigma Super TFE Agip
Havoline Motor Oil Texaco Agip Sigma Ultra TFE Agip
Ursa Super LA Texaco Amsoil 10W30 Amsoil
Total rubia S Total Antar Maxolia 10W40 Antar
Unocal Firebird HD Motor Unocal Aral Extra Turboral Aral
Oil SAE 10W40
Aral High Turboral Aral
SAE 10W40
Aral Super Turboral Aral
SAE 5W30
Aral Mega Turboral Aral
SAE 10W40
Avia Synth 5W40 Avia
Avia Multi CFE 10W40 Avia
Avia Multi CFE Plus 10W40 Avia
Avia Turbosynth CFE Avia
10W40
Avia Turbosynth HT-E Avia
10W40
BP Vanellus FE 10W40 BP Oil

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Synth./part-synth. oil for use in retarder: Elf Performance Experty Elf

SAE 0W40, 5W30, 5W40, 5W50, 10W30, 10W40 10W40
Type of oil Supplier Elf Performance Experty Elf

BP Vanellus FE Extra BP Oil FE 5W40
10W40 Esso Ultra Esso
BP Vanellus HT 10W40 BP Oil Esso Ultron Esso
BP Vanellus HT Extra BP Oil Esso Ultra Diesel Esso
10W40
Essolube XTS 301 Esso
Castrol Syntruck SAE Castrol Commercial
5W40 Essolube XTS 501 Esso
Castrol Dynamax SAE Castrol Commercial Fina Kappa First Fina

10W40 SAE 15W40
Castrol Transmax Z Castrol Commercial Fina Kappa Ultra Fina

SAE 10W40
DEA Cronos Synth SAE DEA
5W40 Fina First 5W40 Fina
DEA Cronos Premium HC DEA Titan Unic MC SAE 10W40 Fuchs

SAE 10W40 Titan Unic Plus MC Fuchs
DEA Cronos Premium XL DEA SAE 10W40
SAE 10W40 Titan Cargo MC Fuchs
DEA Cronos Premium FX DEA SAE 10W40
SAE 10W40 Emgard MTF 4200 Henkel
DEA Cronos Premium LD DEA HRD Maxima LD 10W40 Huiles Renault Diesel
10W40
Klübersynth GEM 4-68 Klüber
Elf Ecomax FE 10W40 Elf
Mogul Diesel DTT Plus Koramo
Elf Ecomax FE plus 10W40 Elf 10W40

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Synth./part-synth. oil for use in retarder: Oest gigant Turbo FE Oest

SAE 0W40, 5W30, 5W40, 5W50, 10W30, 10W40 10W40
Trysk Top Tir - Fe 10W40 Paramo
Repsol Competicion 5W40 Repsol
Sintetic 10W40 Gasolina Krafft
Repsol Sintetico Gasolina Repsol
Sintetic 10W40 Diesel Krafft 10W40
Mobil Delvac XHP 10W40 Mobil Oil Repsol Sintetico Diesel
Repsol
Mobil Delvac XHP Extra Mobil Oil 10W40
10W40 Shell Myrina TX 5W30 Shell
Mobil Delvac 1 SHC 5W40 Mobil Oil Shell Myrina TX 10W40 Shell
Carrier Diesel Sint 10W40 Mol Glap Synth D 1040 Sofomil
MC Power 3 SAE 10W40 Motorex Wintershall TFX SRS
MC plus SAE 10W40 Motorex Wintershall TFE SRS
Star-Synt SAE 5W50 Motorex Wintershall TFG SRS
Multimiles MM-1 Bioil Multimiles Ursa Super TDX 10W40 Texaco
chem. 0W30/40
Total rubia TIR 8600 Total
Multimiles Fut. 3 MM-23 Multimiles
D-2 10W40 Wameco Green Rallenter Wameco
Fluid N
F-H 10W40 Wameco Red Rallenter Wameco
Fluid N
F-HP 10W40
F-P 5W50

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Synthetic oil for use in retarder:

SAE 75W-80W

Emgard MTF Henkel

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Cooling water quality
Caution! Risk of poisoning!
Fuels are harmful to health!

If a fuel was swallowed, visit immediately a doctor!
Keep fuels away of children!
The coolant may not be discharged into the sewage system. It must be brought to the recycling as well
as to the waste disposal.
The legal regulations as well as regulations for sewage can deviate country-specific and are to be
heeded with the waste disposal of used coolants.
Before use of the coolants, the safety-data-sheets and product-information of the respective
manufacturer are to be heeded and to keep.
The coolant is a mixture of water and corrosion-/anti-freeze agent.From reasons of the corrosion-protec-
tion and to the increase of the boiling point, the coolant must remain non-seasonal in the cooling system.
Coolants have to be renewed after three years, because the corrosion-protection will reduce itself.
Water
Water itself is not allowable as coolant, even if anti-freeze-qualities are not necessary. The water of the
coolant must fulfil defined requests, that frequently, however not always meet the drinking water quality.
If the water-quality is not sufficient, the water must be purified.
Information about this can be ordered from us.

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Corrosion-/anti-freeze agent
To avoid damages in the retarder cooling-system:
• Use only a released corrosion-/antifreeze agent, that is released expressly for aluminium by the
manufacturer. The use of purely glycol is not allowed.
• With refills (after coolant-loss) a proportion of corrosion-/antifreeze agent of 50 vol.-% in the coolant
(antifreeze to -37 °C) must be secured.
• Do not use more than 55 vol. -% (= maximum antifreeze) corrosion-/antifreeze agent.

• The feature of antifreeze will be reduced and the heat rejection poor.
Ratio for coolant

Antifreeze Water Corrosion-/
to °C Vol.-% antifreeze agent
vol.-%
-37 50 50
approx. -45 45 max. 55
In exceptions, if no corrosion-/antifreeze agent is available and no antifreeze is required (for example

tropics), 1 vol. -% = 10 cm3/litre refining agent must be used. In this case, the coolant is to be renewed
annually.
Continuing information can be taken from the Voith cooling-water list. This can be ordered from Voith
Turbo with the Voith item-number 67.2224.10.

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Remark:
Gearbox spare part recommendation list Terms of items from DaimlerChrysler-EPC-documentation
26/350/083
26/350/080
26/100/056 26/250/047
26/100/206
26/100/053
26/350/101
26/100/059 26/860/026
26/100/032
26/860/017
25/250/020 26/860/014
26/100/038
26/860/026
26/100/014
26/100/008
26/100/197
26/100/203 26/100/200
26/100/023 26/100/194
26/400/089
26/100/029 26/400/083 26/100/128
26/100/128 26/100/122
26/100/125 26/100/128
26/100/125
25/250/008 25/250/113 26/250/068 26/100/113

26/350/071
26/350/ 26/100/107 26/100/116

26/100/119
25/250/068
26/350/065
25/250/110

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6101 3300
Retarder spare part recommendation list
6100 4100
6101 3100
9000
3300 3850 2000/1
3850
2800/1 3800 3900

8000
6600
6700 4000
3700 5400
2900 2300 5500
5600
7500
2301
25000
109
850
6400
7300 20100
5200 7600 20000
20300
5300
7500 20200
103 7300 20300
2600
3500 6700
5200
2500/1 6600
5300
20000
3100 4100 20100
20200
107 6700
4200 4200
6600 20300
M+P-07A-1504b

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Retarder stage switch

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Ersatzteil-Katalog - Stand: 2000-04-13
Gruppe Katalog Benennung Typ Zeichnung-/ET-Katalog-Nr. Blatt Nr.

Group Identification No Designation Type Drawing-/SP-Catalog-No. Sheet No.
01 53.2654.90 ET-VORSCHLAGSLISTE RET. 115 E 1
ZPOSNR Sachnummer Benennung Abmessung Norm-Nr. GR BTA ET-KZ Menge

Draw.it.No Identification No Designation Dimensions Standard No. Quantity
Revisions-Nr.:
Bemerkung.: ET - Vorschlagsliste
AZ-Nummer:
Typ: Retarder 115 E
Kennwort: Schulungsmappe
Betriebsanl.Nr.:
Werkstatthandb.:
Kunden-Nr.: 137975
Kunden-Code:
53.2993.00 RETARDER 115 01 1

SP.PARTS CATALOGUE
103 01 . 0907 . 86 VERSCHLUSSSCHRAUBE VS M12X1,5 VN 1638 1

SCREW PLUG
Kunden-Sachnr.: A 000 997 68 32
107 91 . 2769 . 10 VERSCHLUSSSCHRAUBE M24X1,5 OHNE ZCHN 1

SCREW PLUG

SCREW PLUG
850 91 . 2493 . 10 AUSSENRING M802011AP OHNE ZCHN 1

OUTER RING
2300 53 . 1332 . 11 PROFILENTLUEFT.BGR. D30X38 DRUCKG. 53.1332.11 1

HOUSING VENTILATION
beinhaltet Pos. 2301
INCLUDES POS. 2301
2301 01 . 0647 . 56 RUNDDICHTRING 55X3 VN 3014 1

O-RING
2600 67 . 1491 . 10 DICHTUNG UNTEN 67.1491.10 1

SEAL
2900 67 . 1497 . 10 DICHTUNG PE-DECKEL 67.1497.10 1

SEAL
3100 53 . 9454 . 20 KOMBI-6KT.SCHRAUBE M 8 X 30 53.9451.20 22

HEXAGON BOLT

HEXAGON BOLT
3500 67 . 2418 . 10 VERSCHLUSSCHRAUBE MIT SIEB 67.2418.10 1

SCREW PLUG


3700 53 . 9490 . 22 PROPORTIONAL-VENTIL DIGIPROP 67.1098.22 1

PROPORTIONAL VALVE
3800 67 . 1703 . 10 DAEMPFUNGSPLATTE 160X70X22 67.1703.10 1

DAMPING PLATE
Bei Sandgussventil 67.1091.10 ist der
Reparatursatz 53.2672.10 zuverwenden.

O-RING

HEXAGON BOLT
nur noch fuer Befestigung der Dõmpfungsplatte
fuer andere Anwendungen ==> Ersatz 53.9452.20
ONLY FOR MOUNTING OF DAMPING PLATE,
FOR OTHER USES REPLACED BY 53.9452.20
4000 01 . 0837 . 09 SECHSKANTMUTTER M8 DIN 6927 4

HEXAGON NUT

SCREW PLUG

SCREW PLUG
5200 67 . 0150 . 22 TEMPERATURGEBER M14X1,5/SW21 67.0150.22 2

THERMOCOUPLE
5300 01 . 0044 . 47 DICHTRING A14X20 DIN 7603 2

SEAL RING
Kunden-Sachnr.: N 007603 014106
5400 91 . 2474 . 10 WELLENFEDER SSB-0118 OHNE ZCHN 2

UNDULATED WASHER
5500 53 . 3467 . 10 SCHEIBE (DAEMPFER) D30X4 53.3467.10 2

WASHER
5600 90 . 9270 . 10 SICHERUNGSRING JL 30X1,2 90.9270.10 2

CIRCLIP
6100 67 . 1947 . 10 ROHR M. RDR / LUFT 67.1947.10 1

PIPE
beinhaltet Pos. 6101
INCLUDES POS. 6101
6101 01 . 0041 . 78 RUNDDICHTRING 15,3X2,4 VN 3014 2

O-RING


6400 67 . 2378 . 13 WAERMETAUSCHER 67.2378.13 1

HEAT EXCHANGER
6600 53 . 9461 . 10 6KT.SCHRAUBE M.FL. M14 X 40 53.9458.11 4

HEXAGON BOLT

O-RING

O-RING

O-RING
8000 67 . 2043 . 10 ZWISCHENPLATTE 196X144X2 67.2043.10 1

INTERMEDIATE PLATE
9000 53 . 8258 . 10 DRUCKSENSOR 0-4 BAR 53.8258.10 1

PRESSURE SENSOR
20000 67 . 2069 . 20 WASSERSTUTZEN AD 52 67.2069.20 2

WATER SOCKET
20100 67 . 2178 . 10 DICHTUNG WASSERSTUTZEN 67.2178.10 2

SEAL

HEXAGON BOLT
25000 67 . 2674 . 10 AUSGLEICHSCH.(AUSW) R115 AN GO4 O.Z. 1

SET OF SHIMS
bestehend aus A 629 261 01 52 bis A 629 261 33 52
25100 67 . 2683 . 10 O-RING D 14 X 4 O.Z. 2

O RING
25200 67 . 2676 . 10 SCHRAUBE M10X70 O.Z. 5

BOLT
Kunden-Sachnr.: A 914 26 01 00 37
25300 67 . 2675 . 10 SCHRAUBE M10X60 O.Z. 17

BOLT
Kunden-Sachnr.: A 914 126 01 00 51

Aftersales Service Manual Gearbox-Retarder-System GO170 - GO210 With R 115 E

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Aftersales Service Manual Gearbox-Retarder-System GO170 - GO210 With R 115 E

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Training Aftersales Service Manual

Gearbox-Retarder-System GO170 - GO210 with R 115 E

'DLPOHU&KU\VOHU$* Aftersales Service Manual Gearbox-Retarder-System 9RLWK7XUER*PE+ &R.*

4 Diagnosis / Troubleshooting Gearbox .....................................................4/1

'DLPOHU&KU\VOHU$* Aftersales Service Manual Gearbox-Retarder-System 9RLWK7XUER*PE+ &R.*

5 Diagnosis / Troubleshooting Retarder.....................................................5/1

6 Removing, Installing Gearbox .................................................................6/1

7 Removing, Installing Retarder .................................................................7/1

'DLPOHU&KU\VOHU$* Aftersales Service Manual Gearbox-Retarder-System 9RLWK7XUER*PE+ &R.*

8 Repair Gearbox .......................................................................................8/1

'DLPOHU&KU\VOHU$* Aftersales Service Manual Gearbox-Retarder-System 9RLWK7XUER*PE+ &R.*

10 Control Parts Retarder ..........................................................................10/1

Operating Specifications: - Oil Specifications Gearbox

Spare Parts Lists

'DLPOHU&KU\VOHU$* Aftersales Service Manual Gearbox-Retarder-System 9RLWK7XUER*PE+ &R.*

is associated for general notices for a better handling during maintenance

'DLPOHU&KU\VOHU$* Aftersales Service Manual Gearbox-Retarder-System 9RLWK7XUER*PE+ &R.*

• The switched-on retarder will not secure the parked vehicle!

• Unauthorized changes at the gearbox-retarder-system as well as the use of spare parts,

• Repair and maintenance work may only be enforced by qualified specialist-staff.

'DLPOHU&KU\VOHU$* Aftersales Service Manual Gearbox-Retarder-System 9RLWK7XUER*PE+ &R.*

gearbox-design-group image board part in drawing

• The pertinent accident-prevention-regulation, other broadly rules of the security-technology and

'DLPOHU&KU\VOHU$* Aftersales Service Manual Gearbox-Retarder-System 9RLWK7XUER*PE+ &R.*

DaimlerChrysler AG Voith Turbo GmbH & Co. KG

Telephone 07225 / 61-65 56 Telephone 07951 / 32-401, -422

Copyright October 1999 - Voith Turbo / DaimlerChrysler

'DLPOHU&KU\VOHU$* Aftersales Service Manual Gearbox-Retarder-System 9RLWK7XUER*PE+ &R.*

2.1 Illustration Gearbox-Retarder-System........................................................2.1/1

2.2 Function and Operation Scheme Gearbox.................................................2.2/1

2.3 Function and Operation Scheme Retarder.................................................2.3/1

2.4 Gearbox Identification ................................................................................2.4/1

2.5 Retarder Identification ................................................................................2.5/1

2.6 Retarder Control-Unit Identification ............................................................2.6/1

'DLPOHU&KU\VOHU$* Aftersales Service Manual Gearbox-Retarder-System 9RLWK7XUER*PE+ &R.*

'DLPOHU&KU\VOHU$* Aftersales Service Manual Gearbox-Retarder-System 9RLWK7XUER*PE+ &R.*

25/250/068 Clutch servo * 26/350/ 4100 6400

26/150/ 25/250/068 26/250/068

26/250/047 26/250/ 26/400/089

'DLPOHU&KU\VOHU$* Aftersales Service Manual Gearbox-Retarder-System 9RLWK7XUER*PE+ &R.*

100/1 Retarder data plate

'DLPOHU&KU\VOHU$* Aftersales Service Manual Gearbox-Retarder-System 9RLWK7XUER*PE+ &R.*

Illustration gearbox force diagram

'DLPOHU&KU\VOHU$* Aftersales Service Manual Gearbox-Retarder-System 9RLWK7XUER*PE+ &R.*

Illustration gearbox-longitudinal section

'DLPOHU&KU\VOHU$* Aftersales Service Manual Gearbox-Retarder-System 9RLWK7XUER*PE+ &R.*

Illustration gearbox-longitudinal section

'DLPOHU&KU\VOHU$* Aftersales Service Manual Gearbox-Retarder-System 9RLWK7XUER*PE+ &R.*

Illustration gearbox-sectional view

'DLPOHU&KU\VOHU$* Aftersales Service Manual Gearbox-Retarder-System 9RLWK7XUER*PE+ &R.*

Oil sump Coolant (water)

1 Heat exchanger complete

'DLPOHU&KU\VOHU$* Aftersales Service Manual Gearbox-Retarder-System 9RLWK7XUER*PE+ &R.*

Description of the function

The switched-on retarder will not secure the parked vehicle.

'DLPOHU&KU\VOHU$* Aftersales Service Manual Gearbox-Retarder-System 9RLWK7XUER*PE+ &R.*

Action of the retarder R 115 E with Digiprop control system

'DLPOHU&KU\VOHU$* Aftersales Service Manual Gearbox-Retarder-System 9RLWK7XUER*PE+ &R.*

Temperature pick-ups, water (19), oil (20)

'DLPOHU&KU\VOHU$* Aftersales Service Manual Gearbox-Retarder-System 9RLWK7XUER*PE+ &R.*

Pressure regulating valve (62)

Casing ventilation (23)

Non-return valve (63) inlet

'DLPOHU&KU\VOHU$* Aftersales Service Manual Gearbox-Retarder-System 9RLWK7XUERPE+ &R.

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